Articles and methods of making articles having a concavity or convexity

ABSTRACT

Articles and methods of making an articles having at least one convexity or at least one concavity are described. A first article having at least one concavity is prepared using a molding surface that includes at least one gas bubble. A second article having at least one convexity is prepared using the first article as a mold.

FIELD OF THE INVENTION

The present invention relates to articles and methods of manufacturingarticles that have at least one concavity or convexity.

BACKGROUND OF THE INVENTION

An article having a component with a concave surface or a convex surfaceor an article having a number of concave surfaces or convex surfacesarranged thereon can be used in various industrial fields. In someapplications, the concave or convex surface can function as a lens. Forexample, a sheet-like article having a number of concave surfaces orconvex surfaces arranged thereon can function as an array of lenses suchas an array of microlenses (i.e., microlens array). Such a sheet-likearticle that can be used as a microlens array has recently received agreat amount of attention. Microlens array may be suitable for variousoptical applications including, for example, a display, a semiconductorlaser, and an optical fiber.

Japanese Patent Application Laid-Open No. H11-142609 describes amanufacturing method for a microlens array using an indentation method.According to this manufacturing method, many indentations are formed onthe surface of a mold using a pressing tool. The pressing tool, whichhas a spherical shaped head of different sizes, is repeatedly pressed onthe surface of the mold at regular intervals. A microlens array can thenbe manufactured by compression molding an optical-grade plastic, such asan acrylic polymer, using the mold having the indentations formedthereon. However, the manufacturing method of a microlens array usingthis indentation method requires considerable time and cost because ofthe amount of work needed to form the mold with many indentations.

Japanese Patent Application Laid-Open No. H05-134103 describes amanufacturing method for a microlens array using an electron-beamlithographic method. In this manufacturing method, many microlenses canbe formed on a base sheet using an electron beam. Like the indentationmethod for manufacturing a microlens array, this method requiresconsiderable time and cost. It could take greater than ten days toseveral hundred days to manufacture more than ten thousand to severalhundred thousand microlenses with each microlens having a diameter ofabout 100 micrometers (μm), for example.

Japanese Patent Application Laid-Open No. S62-260104 describes amanufacturing method for a microlens using a laser chemical vapordeposition (CVD) method. In this manufacturing method, a substrate isset in a container filled with a mixed gas composition, a laser beam isirradiated on the substrate to decompose the gas composition, and a lensmaterial is deposited on the substrate to form the microlens. Thedesired shape can be obtained by changing the energy distribution of thelaser beam to vary the amount of material deposited on the substrate.However, because each microlens is formed individually by finelychanging the energy distribution of the laser beam, this manufacturingmethod is slow and costly.

Japanese Patent Application Laid-Open No. H05-134103 describes amanufacturing method for a microlens array that includes preparing alattice frame, placing a resin within the lattice frame, and melting theresin to form curved surfaces suitable for microlenses by means of thesurface tension of the melted resin. Although an article having a convexsurface can be manufactured relatively easily with this manufacturingmethod in comparison with the aforementioned electron-beam lithographicmethod and laser chemical vapor deposition method, it is necessary toprepare the lattice frame using a photoresist prior to formingmicrolenses. The method of preparing the lattice frame can becomplicated. Therefore, the overall steps of manufacturing a microlensarray using this method can be time consuming and costly. Further,because this manufacturing method includes the step of melting thephoto-resist or resin material, the range of suitable materials that canbe used is limited. It can be difficult to find materials that havesuitable melting properties as well as suitable optical properties.

C. Y. Chang et al. reported a manufacturing method for a microlens arraymade of a resin material in Infrared Physics & Technology, 48, pp.163-173 (2006). In this manufacturing method, a resin film is set on amold disposed in a closed chamber and then heated. High gas pressuresare used to extrude the resin film into dimples of the mold, therebyforming convex surfaces. The size and shape of the convex surfaces thatcan be formed are limited, however, because the hardened resin film mustbe reheated to form the microlenses. Additionally, since this methodinvolves high-temperatures and high gas pressures, the manufacturingcost can be high.

Easier methods are desired for manufacturing an article having at leastone concavity or at least one convexity on its surface. Moreparticularly, easier methods are desired for manufacturing an articlehaving at least one micro-concavity or at least one micro-convexity onits surface.

SUMMARY OF THE INVENTION

The present invention relates to articles and to methods ofmanufacturing the articles that have at least one concavity orconvexity. More particularly, an article having at least one concavityis manufactured using a molding surface that includes at least one gasbubble. This article having at least one concavity can then be used as asecond mold to form a second article having at least one convexity.

One aspect of the present invention is a method of making an articlethat has a surface comprising at least one concavity. The methodcomprises using at least one gas bubble deliberately introduced toimpart the at least one concavity to the surface of the article.

In some embodiments of this method, multiple gas bubbles arranged in apattern are used to impart an arranged pattern of concavities to thesurface of the article.

Another aspect of the present invention is a method of making a secondarticle that has a surface comprising at least one convexity. The methodcomprises using the article having at least one concavity as a secondmold to impart the at least one convexity to the surface of the secondarticle. In some embodiments of this method, the first article that isused as the second mold has an arranged pattern of concavities and thesecond article has an arranged pattern of convexities.

Yet another aspect of the present invention is an article that has asurface comprising an arranged pattern of concavities, wherein gasbubbles imparted the arranged pattern of concavities to the surface ofthe article during its manufacture.

Still another aspect of the invention is a second article having asurface comprising an arranged pattern of convexities. The arrangedpattern of the convexities is an inversion of an arranged pattern ofconcavities of a second mold, wherein gas bubbles imparted the arrangedpattern of concavities to a surface of the second mold during itsmanufacture.

In another embodiment, a molding surface includes a plurality of gasbubbles, where the bubbles form a lattice pattern. In some cases, thegas bubbles include concavities or convexities. In some cases, the gasbubbles have linear side walls. In some cases, the lattice patternincludes a row pattern, or a zigzag pattern, or a radial pattern.

In another embodiment, a surface includes a first lattice pattern ofconcavities or convexities and a second lattice pattern of prisms. Insome cases, the concavities or convexities of the first lattice patternand the prisms of the second lattice pattern alternate. In some cases,the concavities or convexities have spherical or substantially sphericalsurfaces. In some cases, the concavities or convexities have the sameshape. In some cases, the concavities or convexities have the same size.In some cases, the concavities or convexities are in direct contact withgas bubbles. In some cases, the concavities or convexities are in directcontact with a hardenable fluid. In some cases, the concavities orconvexities are in direct contact with a hardened fluid.

In another embodiment, an article includes a plurality of concavities,where each concavity is surrounded by walls. In some cases, theconcavities are arranged at predetermined positions. In some cases, theconcavities form a lattice pattern. In some cases, the walls have prismportions. In some cases, the article also includes a hardened fluid.

In another embodiment, an article includes a plurality of convexities,where each convexity is surrounded by grooves. In some cases, theconvexities are arranged at predetermined positions. In some cases, theconvexities form a lattice pattern. In some cases, the grooves haveprism portions. In some cases, the article also includes a hardenedfluid.

In another embodiment, an article includes a hardened fluid thatincludes a structured surface. The structured surface includes a latticepattern of convexities or concavities. The article further includes ahardenable fluid that is adjacent to the hardened fluid. In some cases,the hardenable fluid includes a structured surface.

In another embodiment, an article includes a mold that includes aplurality of depressions and a fluid that covers the mold. The articlefurther includes one or more gas bubbles in each depression. The one ormore bubbles form a concavity in the fluid. In some cases, the pluralityof depressions form a lattice pattern. In some cases, each of theplurality of depressions has a pointed bottom. In some cases, each ofthe plurality of depressions has an edge line at the bottom. In somecases, each of the plurality of depressions comprises a pyramid portion.In some cases, each of the plurality of depressions includes one or moreplanar sides. In some cases, each of the plurality of depressions has ashape that tapers. In some cases, the one or more gas bubbles in eachdepression include a sidewall. In some cases, the concavity in the fluidincludes an over-hang portion.

In another embodiment, a display device includes a backlight that emitslight and a display panel that displays an image. The display devicefurther includes an optical film that is disposed between the backlightand the display panel. In some cases, the optical film has an opticalgain of at least 1.2. The optical film has a structured major surfacethat includes a plurality of discrete structures. Each discretestructure includes a concavity or a convexity and a side wall. In somecases, the side wall includes a prism portion. In some cases, theoptical gain of the optical film is at least 1.3. In some cases, theoptical gain of the optical film is at least 1.4. In some cases, theoptical gain of the optical film is at least 1.5. In some cases, thestructured major surface of the optical film faces the backlight. Insome cases, the structured major surface of the optical film faces thedisplay panel. In some cases, the concavity or the convexity includes asubstantially spherical concavity or convexity.

In another embodiment, an article includes a mold that has a firststructured surface that includes a plurality of walls that separate aplurality of depressions. The article further includes a hardenablefluid that covers the first structured surface of the mold and contactsat least the plurality of the walls. If the fluid is hardened andremoved from the mold, then the removed hardened fluid has a secondstructured surface that is substantially different than the inverse ofthe first structured surface. In some cases, the second, but not thefirst, structured surface has a plurality of concavities or convexities.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A to 1D are schematic sectional views exemplifying one embodimentof a method of manufacturing a first article having at least oneconcavity.

FIGS. 1E to 1G are schematic sectional view exemplifying one embodimentof a method of manufacturing a second article having at least oneconvexity.

FIG. 2A is a schematic view exemplifying one embodiment of a mold havingmultiple depressions.

FIG. 2B is a schematic view exemplifying another embodiment of a moldhaving multiple depressions.

FIG. 3A is a schematic sectional view exemplifying another embodiment ofa method of manufacturing a first article having at least one concavity.

FIG. 3B is a schematic sectional view exemplifying another embodiment ofa method of manufacturing a second article having at least oneconvexity.

FIG. 4 is a schematic sectional view showing conditions for a bubble ofgas existing at the surface of the mold in a depression (i.e., the gasbubble is positioned between the mold surface and the hardenable fluid).

FIG. 5 is an exemplary diagram showing the position of gas bubbleswithin a depression of a mold.

FIGS. 6A to 6D are schematic sectional views exemplifying otherembodiments of a method of manufacturing a second article having atleast one convexity.

FIGS. 7A to 7D are schematic sectional views exemplifying anotherembodiment of a method of manufacturing a first article having at leastone concavity.

FIGS. 7E to 7G are schematic sectional views exemplifying anotherembodiment of a method of manufacturing a second article having at leastone convexity.

FIG. 8 is a schematic perspective view showing one example of an articlehaving concavities arranged in a lattice pattern.

FIG. 9 is a scanning electron micrograph showing one example of a secondarticle having convexities arranged in a lattice pattern.

FIGS. 10A and 10B are schematic top views showing examples of a moldhaving multiple depressions arranged in a lattice pattern.

FIG. 11 is a schematic perspective view showing another example of anarticle having multiple concavities arranged in a lattice pattern.

FIG. 12 is a scanning electron micrograph showing another example of asecond article having multiple convexities arranged in a latticepattern.

FIG. 13 is a schematic perspective view showing yet another example ofan article having concavities arranged in a lattice pattern.

FIG. 14 is a schematic perspective view showing yet another example of asecond article having convexities arranged in a lattice pattern.

FIGS. 15A and B are scanning electron micrographs of articles made usingtreated and untreated molding surfaces, respectively.

FIG. 16 is a display device that includes a direct-lit backlight.

FIG. 17 is a side-lit backlight.

FIGS. 18A and 18B are schematic cross-sectional views of articles havingprisms separating convexities or concavities.

DETAILED DESCRIPTION OF THE INVENTION

Articles are provided that have at least one concavity or at least oneconvexity. Methods of making these articles are also provided. The atleast one convexity or concavity of the articles can be used, forexample, as a lens or as an array of lenses. In some embodiments, the atleast one convexity or concavity of the article can be used as amicrolens or an array of microlenses (i.e., a micrlens array). As usedherein, the term “microlens” refers to a lens having a dimension such asa diameter in the range of about 0.1 micrometer to about 1000micrometers. The microlens corresponds to a micro-convexity ormicro-concavity on the surface of the article. As used herein, the terms“micro-concavity” and “micro-convexity” refer respectively to aconcavity or convexity having a diameter in the range of about 0.1micrometer to about 1000 micrometers. As used herein, the term“diameter” when referring to a concavity or convexity corresponds to thelargest cross-sectional dimension.

According to one aspect of the present invention, an article that has asurface comprising at least one concavity can be manufactured. Duringmanufacture, at least one gas bubble is deliberately introduced toimpart the at least one concavity to the surface of the article. Moreparticularly, the article is manufactured using a molding surface thatincludes at least one gas bubble. That is, an article can bemanufactured by a method the comprises: (a) providing a hardenablefluid; and (b) molding the article from the hardenable fluid using amolding surface comprising at least a portion of an outer surface of agas bubble.

Multiple concavities such an arranged pattern of concavities can beformed on the surface of the article using a molding surface thatincludes a plurality of gas bubbles located at different positions onthe molding surface. That is, an article with an with an arrangedpattern of concavities can be manufactured using a method thatcomprises: (a) providing a hardenable fluid; and (b) molding the articlefrom the hardenable fluid using a molding surface comprising at least aportion of an outer surface of multiple gas bubbles, wherein themultiple gas bubbles are arranged in the pattern on the molding surface.

A smooth concave surface, which is the inversion of a portion of thesmooth convex surface of the gas bubble, can be imparted to the article.In contrast to this relatively easy manufacturing method, similarsurfaces have conventionally been formed using complicated manufacturingprocesses.

The terms “a”, “an”, and “the” are used interchangeably with “at leastone” to mean one or more of the elements being described.

The term “at least one concavity” refers to a single concave surface orto multiple concave surfaces. The single or multiple concave surface canbe imparted to the article using a single gas bubble introduced at asingle position on the molding surface or using multiple gas bubblesintroduced at a plurality of positions on the molding surface. Multipleconcavities can be located or arranged in random or arbitrary positionsor arranged in a pattern on the surface of the article.

As used herein, the term “deliberately introducing” means introducinggas bubbles for the purpose of using them as a substantial tool in theprocess of making the articles. That is, the gas bubbles are part of themolding surface that is used to impart the at least one concavity to thesurface of the article. In some embodiments, the term deliberatelyintroducing means not removing or entrapping any gas bubbles that mayalready be present. For example, deliberately introducing can mean notremoving any gas bubbles that may be positioned in one or moredepressions of a mold during application of the hardenable fluid to aportion of the mold. That is, deliberately introducing can meanentrapping a gas bubble in a depression of a mold prior duringapplication of the hardenable fluid to a portion of the mold. Anentrapped gas bubble is part of the molding surface that contacts thehardenable fluid.

In some embodiments, an article that has a surface comprising anarranged pattern of concavities can be manufactured. During manufacture,gas bubbles are supplied at a plurality of positions to impart thearranged pattern of concavities to the surface of the article. Morespecifically, the articles are manufactured using a molding surface thatincludes a plurality of gas bubbles arranged in a pattern thatcorresponds to the pattern of concavities imparted to the article. Thearticle having the arranged pattern of concavities can be easilymanufactured.

The “arranged pattern of concavities” is a pattern of a plurality ofconcavities arranged at predetermined positions, arranged with somedegree of regularity, or arranged in any desired manner. For example,the arranged pattern of concavities can include an arranged row pattern,an arranged lattice pattern such as an arranged square lattice pattern,an arranged zigzag pattern, or an arranged radial pattern. The arrangedpattern of concavities need not be formed evenly on the entire article,but may be formed in only a portion of the article. The pattern ofconcavities may vary or remain the same over any portion of the article.For example, similar or different patterns can be used within the sameplane. The concavities within the pattern can be of the same size andshape or can have different sizes and shapes.

Any suitable gas can be used to form the gas bubble that imparts aconcavity to the surface of an article. For example, the gas can be airor an inert gas including nitrogen and argon. The molding surface thatis used to form the article includes a portion of the outer surface ofat least one gas bubble. The outer shape of the gas bubble included inthe molding surface, which is in contact with the hardenable fluid, canbe inversely transferred to the article. Since gas bubbles with variousshapes and sizes having diameters ranging from a few nanometers toseveral centimeters or more can be included in the molding surface, itis possible to form concavities with a wide range of shapes and sizes.Further, when multiple concavities are formed in the article, themultiple concavities can have the same size and shape or can havedifferent sizes and shapes. That is, the molding surface can includemultiple gas bubbles having different sizes and shapes or the same sizeand shape.

One embodiment of the article that has a surface comprising at least oneconcavity can be manufactured according to the following processes: (a)providing a mold having a mold surface; (b) applying hardenable fluidonto at least a portion of the mold surface; (c) deliberatelyintroducing at least one gas bubble between the mold surface and thehardenable fluid; and (d) hardening the hardenable fluid to form anarticle having the at least one concavity on the surface thereof andimparted thereto by the gas bubble. The article is typically removedfrom the mold.

This method can be used to form a single concavity on the surface of thearticle or a plurality of concavities on the surface of the article. Ifmultiple concavities are formed, these multiple concavities can bepositioned in any manner on the surface of the article. In some exampleswhere multiple concavities are formed, the multiple concavities arearranged in a pattern.

An article that has a surface comprising an arranged pattern ofconcavities can be manufactured according to the following processes:(a) providing a mold having a mold surface; (b) applying hardenablefluid onto at least a portion of the mold surface; (c) providing gasbubbles at multiple, separate positions between the mold surface and thehardenable fluid, wherein the separate positions are selected based onthe arranged pattern; and (d) hardening the hardenable fluid to form anarticle having the arranged pattern of concavities on the surfacethereof and imparted thereto by the gas bubbles. The article istypically removed from the mold.

The “mold surface” is the actual surface of the mold. When a gas bubbleis introduced between the mold surface and the hardenable fluid, thehardenable fluid is in direct contact with the actual surface of themold in at least one location and with a gas bubble in at least oneother location. The combination of the actual mold surface and thesurface of at least gas bubble provide a molding surface. That is, asused herein, the term “molding surface” refers to the surface that is indirect contact with the hardenable fluid. The shape of the moldingsurface (specifically, the inverted shape of the molding surface) can beimparted to a surface of an article formed when the hardenable fluid ishardened. A concavity on the surface of the article corresponds to aposition where the hardenable fluid is in contact with a gas bubbleduring the hardening process. Thus, the shape and size of the portion ofthe gas bubble in contact with the hardenable fluid can be imparted tothe hardened article to provide one or more concavities.

Any suitable organic material, inorganic material, or organic-inorganiccomposite material can be used as a material for the mold. Someexemplary materials for the mold include a resin (e.g., a polymericresin), a metal, a glass, a ceramic, or a clay. The mold can be composedof one or more pieces. For example, a mold having multiple pieces can becomposed of a first layer having at least one opening and a second layerthat is laminated to the first layer.

The mold typically has depressions. These depressions can correspond tothe opening or the pattern of openings of the first layer of a moldhaving multiple pieces or can be part of a mold that is a single piece.The depressions are often used to provide the at least one gas bubblethat is part of the molding surface. For example, the at least one gasbubble can be entrapped within the depression when the hardenable fluidis applied to a portion of the mold surface.

When depressions of a mold are used to entrap the at least one gasbubble, the article that has a surface comprising at least one concavitycan be manufactured according to the following processes: (a) providinga mold having a mold surface with a depression; (b) applying ahardenable fluid onto at least a potion of the mold surface; (c)entrapping a gas bubble between the mold surface and the hardenablefluid in the depression; (d) hardening the hardenable fluid to form anarticle having a concavity on the surface thereof and imparted theretoby the gas bubble in the depression. The article is typically removedfrom the mold.

When the mold has a plurality of depressions that can be used to entrapthe gas bubbles, the depressions can be arranged in a pattern. Anarticle having an arranged pattern of concavities can be manufacturesaccording to the following processes: (a) providing a mold having a moldsurface with multiple depressions arranged in a pattern; (b) applying ahardenable fluid onto at least a portion of the mold surface; (c)entrapping multiple gas bubbles between the mold surface and thehardenable fluid in the multiple depressions; and (d) hardening thehardenable fluid to form an article having an arranged pattern ofconcavities on the surface thereof and imparted thereto by the multiplegas bubbles in the multiple depressions. The article is typicallyremoved from the mold.

The “hardenable fluid” is a fluid that has enough fluidity to be appliedto a mold, and that can be hardened without regard to the hardeningmethod. Suitable hardenable fluids include, for example, an organicmaterial, an inorganic material, or an organic-inorganic compositematerial that is in the form of a gel, paste, or liquid. Other suitablehardenable fluids include a solution, dispersion, suspension, or thelike obtained by diluting an organic material, an inorganic material, oran organic-inorganic composite material with a suitable solvent (i.e.,an organic solvent or an aqueous-based solvent). Herein, “hardening”refers to the process of making the hardenable fluid hard enough toretain the shape imparted by the molding surface. More specifically, thehardenable fluid becomes hard enough to retain the shape imparted by theat least one gas bubble that is part of the molding surface; theresulting “hardened layer” has at least one concavity. The hardenedlayer is the product formed upon hardening of the hardenable fluid.

When an organic material is included in the hardenable fluid, a resinmaterial or the precursor of a resin material can be used. Thehardenable fluid can, for example, include monomers or polymers that arepolymerized, cured, or crosslinked when hardened. As the “hardeningmethod”, any suitable method can be used including, but not limited to,polymerization of a polymerizable resin, cooling a thermoplastic resinto at least a softening temperature, or drying a solvent. Exemplaryresin materials include, but are not limited to, a reactive resin suchas photo-curable resin that can be hardened by polymerization whenirradiated with radiation (e.g., ultraviolet rays, visible light, orelectron beam), a thermoset resin that is hardened by heat-orientedpolymerization, a reactive resin that can be hardened byoxidization-oriented polymerization, a reactive resin that can behardened by reduction-oriented polymerization, or a thermoplastic resinthat can be hardened when cooled to at least a softening temperature, orthe like.

In some applications, a soluble resin can be used as the hardenablefluid. Suitable soluble resins include a water-soluble resin dissolvedin water, an organic solvent-soluble resin dissolved in an organicsolvent, or the like. If these soluble resins are used as a mold to forma second article, they can often be removed from the second article bydissolution.

When an inorganic material is used as a hardenable fluid, variousinorganic materials can be used such as a glass, concrete, plaster,cement, mortar, ceramics, clay, and metal. These materials can often behardened by heating or removing water. It is also possible to use anorganic-inorganic composite material, which can be a composite of any ofthe above mentioned organic materials and inorganic materials, as thehardenable fluid.

The step of applying a hardenable fluid onto at least a portion of themold surface can be achieved by any known method. In some methods ofapplying the hardenable fluid, a mold having depressions is used and thehardenable fluid is applied so that the depressions are not filled orare only partially filled. Some suitable application methods includecoating, spraying, injecting, brushing, or pouring the hardenable fluidonto at least a portion of the mold surface. Coating can include, forexample, adding the hardenable fluid to a surface and spreading thehardenable fluid over at least a portion of that surface. In manyexamples, the application method includes coating and any suitablecoating method can be used. In some coating methods, the hardenablefluid is applied using a knife coating method. An optimal applicationmethod can be selected based on the type of hardenable fluid, thedesired shape of an article, the desired size of the article, and soforth.

The hardenable fluid can be applied onto the mold surface before the gasbubble is provided or at the same time the gas bubble is provided. Inmany embodiments, the at least one gas bubble is present while applyingthe hardenable fluid to the mold surface. For example, the gas bubblecan be present in a depression on the mold. The gas bubble can beentrapped within the depression during the application of the hardenablefluid to the mold surface. The size, shape, and position of the gasbubble provided often can be selected and varied. For example, if thegas bubbles are provided using depressions in a mold, the size, shape,and locations of these depressions can be varied.

The hardenable fluid is in contact with the molding surface. That is,the hardenable fluid is in contact with at least one gas bubble in atleast one position and in contact with the mold surface in at least oneother position. When the hardenable fluid is hardened, the at least oneconcavity is formed in the portion of the hardened layer that was incontact with the at least one gas bubble that is part of the moldingsurface. When a hardenable fluid is hardened, the position of the atleast one gas bubble can be controlled to be located at a predeterminedposition between the mold surface and the hardenable fluid. For example,the gas bubble can be confined within a depression of the mold. The sizeand the shape of the depression can influence the size and shape of thegas bubble as well as the size and shape of the resulting concavity inthe hardened layer. The size and shape of the depression can be variedto provide concavities of different sizes and shapes. Multiple gasbubbles can be provided, for example, by using a mold that containsmultiple depressions. If multiple gas bubbles are provided, the size andshape of each gas bubble can be the same or different.

The above mentioned processes to manufacture an article can be carriedout in the air. In this embodiment, an article having at least oneconcavity or an arranged pattern of concavities can be manufactured witha simple device configuration that does not require special devices suchas an environmental chamber. The at least one gas bubble can beprovided, for example, by entrapment within at least one depression of amold.

A gas bubble often tends to form a spherical surface based on thebalance of all the forces that can affect its shape. These forcesinclude a summation of the interface energy between the gas bubble andthe hardenable fluid, the interface energy between the mold surface andthe hardenable fluid, and the interface energy between the mold surfaceand the gas bubble. In addition to these forces, other process variablesin the vicinity of the region where the gas bubble contacts thehardenable fluid such as, for example, buoyancy, gravity, and viscosityof the hardenable fluid can influence the shape of the gas bubble. Whenan approximately uniform force is applied to the surface of the gasbubble or when approximately symmetrical forces are applied to the topof the gas bubble, the gas bubble does not deform and has a relativelyuniform and smooth convex surface. This shape is often a substantiallyspherical convex surface adaptable to a lens or the like. The outershape of the gas bubble having a substantially spherical surface can beinversely transferred from the molding surface to the article preparedby hardening the hardenable fluid. Therefore, the concavity imparted bythe portion of the gas bubble that contacts the hardenable fluid cancomprise a concavity at least partially having a substantially sphericalsurface.

As used herein, the term “spherical surface” means that the surface canbe considered to be a portion of a sphere or the surface has a sphericalcurvature. Some spherical surfaces can be considered to be dome-shapedor hemispherical. Other spherical surfaces can cover a smaller or largerportion of a sphere than a hemisphere. As used herein, the term“substantially spherical surface” means that the surface can generallybe considered to be a portion of a sphere but may differ slightly frombeing a perfectly spherical surface. All the substantially sphericalsurfaces can have the same or different curvature and can include amixture of spherical surfaces whose curvatures continuously changedepending on the position.

Some concave surfaces are an asymmetrical surface rather than asymmetrical spherical surface. A concave surface with an asymmetricalshape can be imparted to an article using the outer surface of a gasbubble having an asymmetrical shape. The asymmetrically shaped gasbubble can be formed by applying non-uniform forces to the convexsurface of the gas bubble or by applying a force that has anasymmetrical distribution to the top of the convex surface of the gasbubble.

The articles having at least one concavity can be manufactured using arelatively simple process. A single concavity can be formed on thesurface of the article or a plurality of concavities can be formed thatcan be arranged randomly or in a pattern. The at least one concavity canbe spherical or substantially spherical and can be used as a lens. Anarticle having an arranged pattern of concavities such asmicro-concavities can be manufactured in a simple process that is lesstime consuming and less costly than other known process for makingsimilar articles. Further, it is possible to modify the manufacturingprocess so that it can be performed in continuous manner and so that anydesired size article can be prepared.

According to one embodiment of the present invention, the mold cancomprise at least one depression, and the at least one gas bubble isdeliberately introduced at the molding surface by entrapping it in theat least one depression of the mold while applying the hardenable fluidto the mold surface. That is, the gas bubble is entrapped in thedepression of the mold and is positioned between the mold surface andthe hardenable fluid. The molding surface in contact with the hardenablefluid includes a combination of the mold surface (i.e., the actual moldsurface) and at least one gas bubble.

For example, the mold can comprise an arranged pattern of multipledepressions and a plurality of gas bubbles can be deliberatelyintroduced at the molding surface by entrapping them in the arrangedpattern of multiple depressions of the mold while applying thehardenable fluid to the molding surface. That is, multiple gas bubblescan be entrapped in the plurality of depressions of the mold that arearranged in a pattern. Each of the multiple gas bubbles can be entrappedwithin a depression of the mold between the mold surface and thehardenable fluid. The molding surface in contact with the hardenablefluid includes a combination of the mold surface (i.e., the actual moldsurface) and multiple gas bubbles arranged in a pattern.

In these embodiments, since at least one depression or an arrangedpattern of depressions are provided in the mold beforehand, gas bubblescan be entrapped in the at least one depression of the mold whileapplying the hardenable fluid to the molding surface. The location ofthe at least one depression corresponds to the position of the at leastone gas bubble that is part of the molding surface. The position of theat least one gas bubble corresponds to the location of the concavitiesimparted to the articles prepared by hardening the hardenable fluid incontact with the molding surface. Therefore, the at least one concavitycan be located at a predetermined position on the article certainly andeasily. In addition, because the locations of the depressions correspondto the positions where the concavities are formed in the article,multiple concavities having a high positional accuracy can be formed onthe article.

The volume of a depression in the mold influences the amount of gas thancan be entrapped within the depression between the hardenable fluid andthe mold surface. If there are multiple depressions, the volumes ofmultiple depressions can be similar or any portion of the multipledepressions can be similar. The size of any concavity can be varied byvarying the volume of the depression that entraps that gas bubble thatresults in that particular concavity. For example, a first group ofconcavities can have a first size that is different from a second groupof concavities that have a second size.

Any desired pattern of depressions can be included in the mold. Forexample, the arranged pattern of depressions can include an arranged rowpattern, an arranged lattice pattern such as a square lattice pattern(i.e., a lattice pattern is a pattern with multiple rows, multiplecolumns, or both), an arranged zigzag pattern, or an arranged radialpattern. The depressions within the pattern can be the same size andshape or can be different.

According to the above mentioned embodiments, a gas bubble can beprovided between the mold surface and the hardenable fluid by entrappingit in the depression of the mold while applying the hardenable fluid toat least a portion of the mold surface. For example, a portion of thetotal gas (e.g., air) existing around the mold can be entrapped within aspace between the hardenable fluid and the mold surface while thehardenable fluid is applied to the mold by coating or injection. Anentrapped gas bubble can become part of the molding surface and canimpart a concavity to the hardened layer. In this case, if a coating isapplied, various coating devices, such as, for example, a knife coater,a bar coater, a blade coater, and a roll coater, can be used.

Entrapping the at least one gas bubble can be controlled by adjustingfactors such as, for example, the viscosity of hardenable fluid, thecoating speed, various interfacial tension relationships among thehardenable fluid, the gas and the mold, or the like. Conditions of theentrapped bubble of the gas such as size, shape and position can also becontrolled by the similar factors for entrapping the bubble of the gasmentioned above such as, for example, the size, shape, and position ofthe depressions in the mold. The entire process can be conducted underatmospheric pressure and no evacuation is needed.

Another aspect of the present invention is an article having a surfacecomprising at least one concavity such as an arranged pattern ofconcavities manufactured according the above mentioned manufacturingmethod. During manufacture, one or more gas bubbles impart the at leastone concavity such as the arranged pattern of concavities to the surfaceof the article.

In one embodiment of the article, at least one smooth concave surfacecan be formed using a molding surface that includes at least one gasbubble. If multiple concavities are formed, these multiple concavitiescan be arranged randomly or in a pattern. An arranged pattern ofconcavities can be formed using a molding surface that includes anarranged pattern of gas bubbles. This arranged pattern of gas bubblesoften corresponds to an arranged pattern of depressions in the mold.Each smooth concave surface produced is the inverse of a portion of theouter surface of a gas bubble that is part of the molding surface. Inmany examples, the gas bubble has a substantially spherical surface andthe resulting concavity imparted to the article has a substantiallyspherical surface.

If multiple concavities are arranged in a pattern on the surface of thearticle, the pattern can be of any design. For example, the arrangedpattern can be an arranged row pattern, an arranged lattice pattern, anarranged zigzag pattern or an arranged radial pattern. The concavitiescan all be of a similar size and shape or any portion of the concavitiescan be of a similar size and shape. In some articles having an arrangedpattern of concavities, some or all of the concavities has asubstantially spherical surface.

Additionally, a concavity having an overhang shape (e.g., see 32 a inFIG. 3A), which is difficult to form using conventional mechanicalmachining, can be formed on the surface of the article.

The articles described herein can be used in various fields andapplications. Especially, if the at least one concavity on the surfaceof the article is substantially transparent or translucent to visiblelight and has a substantially spherical surface, the article can be usedin various optical applications. For example, the concavity can functionas a lens such as a microlens. An arrangement of multiple concavitiesthat are transparent or translucent to visible light and that havesubstantially spherical surfaces can be used as an array of lenses suchas a microlens array.

A first article having a surface comprising at least one concavity suchas an arranged pattern of concavities can be used as a mold (i.e., asecond mold) to produce a second article having at least one convexitysuch as an arranged pattern of convexities on its surface. The at leastone convexity on the second articles is the inverse of the at least oneconcavity present on the first article that is used as the second mold.That is, any concavity present in the first article can be imparted tothe second article as a convexity.

The term “at least one convexity” refers to a single convex surface orto multiple convex surfaces. The at least one convex surface can beimparted to the article using a mold with at least one concave surface.An “arranged pattern of convexities” is a pattern of a plurality ofconvexities arranged at predetermined positions, arranged with somedegree of regularity, or arranged in any desired manner. For example,the arranged pattern of convexities can include an arranged row pattern,an arranged lattice pattern such as an arranged square lattice pattern,an arranged zigzag pattern, or an arranged radial pattern. The arrangedpattern of convexities need not be formed evenly on the entire article,but may be formed in only a portion of the article. The pattern ofconvexities may vary or remain the same over any portion of the article.For example, similar or different patterns can be used within the sameplane. The convexities within the pattern can be of the same size andshape or can have different sizes and shapes.

By virtue of using the first article as a second mold to form the secondarticle, the second article that has at least one convexity such asarranged pattern of convexities can be formed using relatively simpleprocesses and relatively short manufacturing times compared to otherconventional methods of forming similar articles. More specifically, asecond article having at least one substantially spherical convexsurface such as an arranged pattern of convex surfaces can be formedusing a first article that has at least one substantially sphericalconcave surface. The at least one convex surface formed in the secondarticle can be, for example, a micro-convexity.

Thus, another aspect of the present invention is a second article thathas a surface comprising at least one convexity such as an arrangedpattern of convexities. The method comprises using the first articlemade by the above mentioned manufacturing method as a second mold toimpart the at least one convexity such as an arranged pattern ofconvexities to the surface of the second article.

The second article can be manufactured by applying a second hardenablefluid to the first article using an application method such as coatingor injection. The second hardenable fluid is applied to the surface ofthe first article that contains at least one concavity. Suitable secondhardenable fluids are often the same types of hardenable fluidsdescribed above that can be used to prepare the first article with atleast one concavity. The second hardenable fluid is typically selectedto be compatible with the first article that is used as the second mold.More specifically, the second hardenable fluid it often selected so thatit does not dissolve or alter the shape and dimensions of the secondmold. The second hardenable fluid can include an organic material,inorganic material, or organic-inorganic composite material that is inthe form of a gel, paste, liquid, dispersion, suspension, or the like.After the hardenable fluid has been applied to the second mold but priorto hardening, a deaeration process can be added to remove entrapped gasbubbles such as entrapped gas bubbles between the surface of the secondmold and the second hardenable fluid. In some instances, the presence ofentrapped gas bubbles can cause defects in the second article.

In some examples, the at least one convexity has a substantiallyspherical surface and the process involves the use of a second mold thathas at least one concavity with a substantially spherical surface. Theat least one concavity in the second mold often has a diameter less than1000 micrometers, less than 100 micrometers, or less than 10micrometers. The at least one convexity formed in the second article hasa diameter comparable to the diameter of the at least one concavitypresent in the second mold. The second mold is prepared using at leastone gas bubble such as an arranged pattern of gas bubbles in a moldingsurface that imparts at least one concavity such as an arranged patternof concavities to the surface of the second mold.

In some exemplary second articles, the at least one convexity has asubstantially spherical surface. If this at least one convexity issubstantially transparent or translucent in the visible region, thesecond article can be used in various optical fields. More specifically,the at least one convexity can be used as a lens such as a microlens andan arranged pattern of convexities can be used as an array of lensessuch as a microlens array.

If there are more than one convexity on the surface of the secondarticle, all or any portion of the convexities can be similar. Forexample, there can be a first group of convexities having substantialsimilarity and a second group of convexities having substantialsimilarity but that are different from the first group of convexities.

A surface of the second article can be covered with the first articlethat serves as the second mold. In this case, the second article is notremoved from the first article during the manufacturing processes. Sucha combined article composed of both the first article and the secondarticle can be used in various fields. For example, when materials withdifferent refractive indexes are used to prepare the first article andthe second article, the combined article can function as a lens even ifthe combined article has a flat surface.

One exemplary process for preparing a first article having at least oneconcavity and a second article having at least one convexity isschematically illustrated in FIGS. 1A to 1G. More specifically, FIGS. 1Ato 1D schematically illustrate one embodiment of a manufacturing methodfor making an article having a surface comprising multiple concavitiessuch as an arranged pattern of concavities. FIGS. 1E to 1G schematicallyillustrate one embodiment of a manufacturing method for making a secondarticle having a surface comprising multiple convexities such as anarranged pattern of convexities.

FIGS. 1A to 1D schematically illustrate one exemplary manufacturingprocess that can be used to manufacture the article 31 having aplurality of concave surfaces 32. FIG. 1A illustrates the step ofproviding a mold 10 that has a plurality of depressions 11. FIG. 1Billustrates the step of applying a hardenable fluid to the mold 10 andproviding gas bubbles 50. The gas bubbles 50 are entrapped in thedepressions 11 and are positioned between the mold surface 12, 13 andthe hardenable fluid 30. FIG. 1C illustrates hardening the hardenablefluid 30 to form the article 31 having the arranged pattern ofconcavities 32 on a surface thereof and imparted thereto by the gasbubbles 50. FIG. 1D illustrates removing the article 31 from the mold10. The article 31 is shown with three concavities 32 but any desirednumber of concavities can be formed. The concave surfaces 32 are formedat locations corresponding to the depressions 11 in the mold and to thelocations of the entrapped gas bubbles 50. The outer shape of the gasbubbles 50 are imparted to the article 31 resulting in the concavities32. Each of the manufacturing processes in FIG. 1A to 1D can be carriedout while the mold 10 is under ambient conditions. The molding processused to manufacture article 31 does not need to be placed in a specialenvironmental chamber.

The gas bubbles 50 are entrapped while applying the hardenable fluid 30to the mold surface with a coating device 40. In many embodiments, thehardenable fluid 30 comprises a hardenable resin. The hardenable fluid30 preferably is applied over the depressions in the mold in such amanner that the multiple depressions are not filled with the hardenablefluid 30. That is, the hardenable fluid 30 preferably does not contactmold surface 13. The gas bubbles 50, however, contact mold surfaces 12and 13 as well as a portion of the hardenable fluid 30 positioned overdepression 11. The molding surface is the surface in contact with thehardenable fluid 30 and includes both the outer surface of the gasbubbles 50 in direct contact with the of the hardenable fluid 30 and anyportion of the mold surface in direct contact with the hardenable fluid30. For example, the portion of the mold between the depressions 11 isin direct contact with the hardenable fluid 30. After applying thehardenable fluid 30 and entrapping the gas bubbles 50, the hardenablefluid 30 is hardened and removed from the mold 10. The resulting article31 has a plurality of concave surfaces 32 to which a portion of theouter shapes of the gas bubbles 50 are imparted.

The construction or article that is shown in FIG. 1B includes a mold 10that includes a plurality of depressions 11 and a fluid 30, such as ahardenable fluid 30, covering mold 10. The construction or article alsoincludes one or more gas bubbles 50 in each depression 11. The one ormore bubbles 50 in each depression forms a concavity 32 in fluid 30. Theplurality of depressions 11 can be arranged in any form that may bedesirable in an application. For example, depressions 11 can be arrangedrandomly. As another example, depressions 11 can be arranged inpre-determined positions and can, for example, form a lattice pattern.

In some cases, such as when depressions 11 are pyramids, thedepsressions can have pointed bottoms. In some cases, such as in thecase of mold 10 shown in FIG. 2B, the depressions can have edge lines atthe bottom. In some cases, depression 11 can have a pyramid portion andcan, for example, be a frustum. In some cases, depression 11 can haveone or more planar sides. In some cases, depression 11 can have atapering shape. In general, depression 11 can have any shape that may bedesirable in an application. Exemplary shapes includes a cube, apyramid, an obelisk, a wedge, a portion of a sphere such as ahemisphere, a portion of an ellipsoid, a catenoid, a cylinder such as aright cylinder, or a cone.

In some cases, such as in the case shown in FIG. 1C, gas bubbles 50 ineach depression include a sidewall and a convex or concave top. In somecases, such as in the case shown in FIG. 3A, the concavity in the fluidcan include an over-hang portion, such as over-hang portion 32A.

The construction or the article shown in FIG. 1C includes a mold 10 thathas a top first structured surface shown in FIG. 1A that includes aplurality of walls 220 separating a plurality of depressions 11, wherewalls 220 and depressions 11 alternate. The construction or the articlein FIG. 1C further includes a hardenable fluid 31 that covers the firststructured surface of the mold. Fluid 31 also contacts at least theplurality of walls 220. In some cases, such as in the case shown in FIG.1C, the fluid also contacts a portion of each depression. Gas bubbles 50prevent fluid 31 from contacting the entire surface of each depression,resulting in fluid 31 having a bottom structured surface 210. If fluid31 is hardened and removed from the mold, then the removed hardenedfluid has a second structured surface 210 (also shown as the bottomstructured surface of layer 31 in FIG. 1D) that is substantiallydifferent than the inverse of the first structured surface (the topstructured surface in mold 10). In the exemplary construction shown inFIG. 1D, the second, but not the first, structured surface has aplurality of convexities or concavities 32.

If the mold contains multiple depressions 11, these multiple depressionscan be arranged randomly or arranged in any desired pattern. In someembodiments, a plurality of depressions 11 can be arranged in a singlerow or in a lattice pattern. As used herein, a mold having a latticepattern of depressions means that there are at least two rows, at leasttwo columns, or at least two rows and at least two columns ofdepressions 11 in the mold. For example, some lattice patterns aresquare lattice patterns where the number of rows is equal to the numberof columns. In other embodiments, the depressions can be arranged in apattern such as a zigzag pattern or a radial pattern.

In the process shown in FIG. 1A, the mold 10 having a plurality ofdepressions 11 is provided. The plurality of depressions 11 can bearranged randomly or arranged in any desired pattern based on the use ofthe resulting articles. The location of the depressions 11 determinesthe positions of the entrapped gas bubbles 50 that impart the at leastone concavity to the surface of the articles. The location of theconcavities 32 on the surface of the article 31 can be selected by thearrangement of the depressions 11 on the mold 10.

Any suitable material can be used to prepare the mold 10. In someexemplary methods, an organic resin material such as polypropyrene,polyethylene, polystyrene, or poly-cyclo-olefin can be used for the mold10. In other exemplary methods, other suitable organic materials,inorganic materials such as metals (e.g., nickel, copper, or brass),glasses or ceramic materials, or organic-inorganic composite materialscan be used. The mold 10 can be flexible or hard. A flexible mold 10often can be more easily handled. However, a mold 10 made of hardmaterial such as a metal or a crystallized polymer often can provideimproved dimensional accuracy. The mold 10 can be any suitable size butthe size is often selected based on the dimensions of the coating device40. Some exemplary molds 10 have a vertical dimension in the range of 1to several thousand millimeters, a horizontal dimension in the range of1 to several thousand millimeters, and a thickness dimension in therange of 10 micrometers to greater than 10 millimeters.

The depression 11 can have any suitable shape. The planar shape observedfrom above the depression 11 can be, for example, a circle, triangle,square, rectangle, ellipsoid, trapezoid, pentagon, hexagon or cross. Forexample, the depression 11 can have a square or rectangular crosssection as shown in FIG. 1A. In this case, a side surface 12 and abottom surface 13 of the depressions may be configured with linearshapes or with curved shapes. The relationship between the shape of thedepression 11 and the shape of the gas bubble 50 will be described indetail later.

FIG. 2A is a schematic view observed from above showing anotherexemplary mold 10 having multiple quadrangular pyramid depressions 11with rectangular planar shaped sides. Each of the pyramids in FIG. 2Ahas a pointed bottom. FIG. 2B is a schematic view observed from aboveshowing yet another exemplary mold 10 having multiple quadrangularpyramid depressions 11 with triangular planar shaped sides. Each of thepyramids in FIG. 2B has an edge line at the bottom.

In other examples, depression 11 can have a triangular cross section andthis cross-sectional shape becomes narrower from the top side toward thebottom side. A side surface may be configured with a linear shape orwith a curved shape. A bottom portion of the depression 11, which is apart of the mold surface, may be configured, for example, with a flatshape as shown in FIG. 1A, a pointed shape, a linear shape, or a roundedshape. In still other examples, depressions 11 can have a trapezoidalcross sectional shape and the cross-sectional width may become narrowerfrom the top towards the bottom or may become wider from the top towardsthe bottom. The side surfaces and the bottom surface may be configuredwith linear shapes or with curved shapes. Any other suitable shapes forthe depressions 11 can be used.

The depressions 11 can have any suitable dimensions. As examples of thesize of the depression 11, the depth can be 0.1 μm or more, 1 μm ormore, or 10 μm or more. The depth can often be 100 mm or less, 10 mm orless, or 1 mm or less. The cross-sectional area of the depressionopening can be 0.01 μm² or more, 0.1 μm² or more, or 1 μm² or more. Thecross-sectional area can often be 1000 mm² or less, 100 mm² or less, or10 mm² or less. The dimensions are not limited, however, to thesevalues.

In the process shown in FIG. 1B, the coating device 40 is set adjacentto the mold 10. The coating composition is coated on at least a portionof the mold 10 with the coating device 40 to form the hardenable fluidlayer 30. The hardenable fluid layer 30 does not fill the depressions11. That is, the hardenable fluid 30 does not contact the mold surface13. At the same time, gas bubbles 50 are provided in the depression 11of the mold 10. The coating process can be performed in the air undernormal atmospheric conditions.

In some embodiments of the coating process shown in FIG. 1B, thehardenable fluid includes a hardenable polymeric resin. Any suitablepolymeric resin can be used alone or in combination with other polymericresins. For example, the hardenable fluid can be a solution of a polymerresin such as a photo-curable resin (e.g., a UV curable resin) or asoluble resin (e.g., a water or organic solvent soluble resin). If themold 10 has a sufficient heat resistance, the polymer resin can be athermoplastic resin or a thermoset resin. Any of the polymeric resinscan contain various additives, such as a thickener, a curing agent, acrosslinking agent, an initiator, an oxidant inhibitor, an antistaticagent, a diluent, a detergent, a pigment, or a dye.

Exemplary photo-curable resins include, but are not limited to, aphotopolymerizable monomer, oligomer, or mixture thereof.Photopolymerizable monomers include acrylate based monomers,methacrylate based monomers, and epoxy based monomers.Photopolymerizable oligomers include acrylate based oligomers,methacrylate based oligomers, urethane acrylate based oligomers, epoxybased oligomers, epoxy acrylate based oligomers, and ester acrylatebased oligomers. A photoinitiator is usually added to the photo-curableresins. When a UV curable resin is used, the resin can usually behardened quickly using ultraviolet radiation without exposing the moldor the like to a high temperature.

Exemplary thermoset resins that can be included in the hardenable fluidinclude, but are not limited to, acrylate based resins, methacrylatebased resins, epoxy based resins, phenol based resins, melamine basedresins, urea based resins, unsaturated ester based resins, alkyd basedresins, urethane based resins, or ebonite based resins. A polymerizationinitiator is typically added to the thermoset resin. The resulting curedpolymeric material can have good heat and solvent resistance.Additionally, if fillers are added, the resulting cured polymericmaterial can be quite strong.

Exemplary thermoplastic resins that can be included in the hardenablefluid include, but are not limited to, polyolefin resins, polystyreneresins, polyvinyl chloride resins, polyamide resins, or polyesterresins.

Exemplary soluble resins that can be included in the hardenable fluidinclude, but are not limited to, water-soluble resins and organicsolvent-soluble resins. Suitable water-soluble resins include, forexample, polyvinyl alcohols, polyacrylic acids, polyacrylic amides, andpolyethylene oxides.

Any suitable hardening method can be used. The hardening method istypically selected based on the composition of the hardenable fluid.Some hardening methods include a drying process to remove water or anorganic solvent. Other hardening methods include exposing the hardenablefluid to actinic radiation such as UV radiation. Still other hardeningmethods include exposing the hardenable fluid to heat or cooling thehardenable fluid.

Any suitable coating device 40 can be used to apply the hardenable fluidlayer 30 to at least a portion of the mold 10. In some embodiments, thecoating device 40 is a knife coater. For example, when a thermoplasticresin is used as the hardenable fluid resin, a heated knife coater thatis heated to a temperature at which the resin has a sufficient fluiditycan be used. In other embodiments, the coating device 40 can be a barcoater, a blade coater, or a roll coater.

To apply the hardenable fluid layer 30 to at least a portion of the mold10, either the coating device 40 or the mold can be moved. In someexamples, the mold is stationary and the coating device is movedadjacent to the mold 10. In other examples, the coating device 40 can bestationary and the mold 10 can be provided from a roll that is passed bythe coating device 40. In these examples, a continuous manufacturingline can be designed to form articles having at least one concavity.

Referring to FIG. 1B, as the coating device 40 moves in the direction ofan arrow A (from left to right), the hardenable fluid layer 30 is coatedon the mold 10. Although FIG. 1B illustrates the application of thehardenable fluid layer 30 to the mold 10 by coating, other applicationmethods such as, for example, injection can be used as long as the otherapplication methods can entrap gas bubbles 50.

The average thickness of the hardenable fluid layer 30 can be anydesired thickness and can be varied according to the article desired. Insome examples, the average thickness of the hardenable fluid layer 30 isabout 10 μm to 100 mm or 10 μm to 10 mm. As the hardenable fluid layer30 is applied to the mold 10, a part of the air existing around the mold10 can be pushed out from the space around the mold 10 as indicated byan arrow B and another part of the air can be entrapped in thedepressions 11. Air that is entrapped in the depression 11 can contactmold surface 12 and 13 of the depression 11 as a gas bubble 50.

The entrapment of gas bubbles 50 within the depressions 11 can becontrolled, for example, by adjusting factors such as the viscosity ofhardenable fluid 30, the coating speed, and the interfacial tensionrelationships among the hardenable fluid 30, the gas bubble 50, and themold 10. For example, if the coating speed is faster than the naturalflow rate of the hardenable fluid on a surface of the depression of themold, a bubble of the gas can be entrapped within each depression of themold. The natural flow rate means the flow rate of the hardenable fluidwhen it is placed on the mold and may be affected, for example, by theviscosity of hardenable fluid and the interfacial tension relationshipsamong the hardenable fluid, the gas, and the mold. If the viscosity ofhardenable fluid is low, gas bubbles 50 can be entrapped by increasingthe coating speed or by changing materials of the mold.

The process is a controlled displacement of gas (air) entrapped in themold 10 and advantageously results in gas bubbles 50 being entrapped inthe mold depressions 11 so that they can be used as part of the moldingsurface. The sizes and positions of the gas bubbles 50 can be controlledby adjusting the process variables including the moving speed of thecoating device 40.

Although the gas bubbles 50 are positioned inside the depressions 11 inFIGS. 1B and 1C, they are not limited thereto. That is, the outersurface of the gas bubbles 50 can be outside the depressions 11. Forexample, the upper portions (i.e., the upper surface) of the gas bubbles50 may extend beyond from the top surface of the mold 10 as shown in thesectional view of FIG. 4. Although a single gas bubble 50 can exist in asingle depression 11 as shown in FIGS. 1B and 1C, more than one gasbubble may exist within a single depression 11.

Referring to FIG. 1C, the top surface of mold 10 and gas bubbles 50define or form a molding surface 210 that imparts structure to thebottom surface of layer 31. Molding surface 210 includes a plurality ofgas bubbles 50 that form a lattice pattern that may include a rowpattern, a column pattern, a zigzag pattern, or a radial pattern, or acombination of such patterns, or any other pattern that may be desirablein an application. In the exemplary molding surface 210, the gas bubblesinclude convexities that impart concavities to layer 31. In general, gasbubbles 50 can include portions that have any shape that may bedesirable in an application, such as concavities, convexities, or planarportions, such as the planar portions of gas bubbles 50 shown in FIG. 1Bor 1C.

In the exemplary construction shown in FIGS. 1B and 1C, bubbles 50 havelinear or planar side walls. In some cases, such as when depressions 11have curved side walls, gas bubbles 50 can have curved side walls.

In the process shown in FIG. 1C, the hardenable fluid layer 30 ishardened to form the hardened layer 31. Any suitable hardening methodcan be used that is compatible with the hardening fluid 30. For example,when the hardenable fluid is a UV curable resin, the hardened layer 31can be formed by irradiating the hardenable fluid layer 30 with a UVlight source to polymerize the resin. When the hardenable fluid layercontains a soluble resin, the hardened layer 31 can be formed by dryingto remove the solvent. When the hardenable fluid is a thermoplasticresin, the hardened layer 31 can be formed by cooling the thermoplasticresin to at least the softening temperature. When the hardenable fluidis a thermoset resin, the hardened coating 31 can be formed by heatingthe thermoset resin to at least the curing temperature.

The hardened layer 31 as shown in FIG. 1C has a plurality of concavesurfaces 32 that result from contacting the outer surface of the gasbubbles 50 during hardening. That is, the outer shapes of the gasbubbles 50, which can have a substantially spherical surface, areinversely transferred to the hardened layer 31. That is, the outershapes of the gas bubbles 50 are part of the molding surface in contactwith the hardenable fluid 30. The hardened layer 31 has the inverseshape of the molding surface.

The gas bubbles 50 are part of the molding surface, which is theoperational surface in contact with the hardenable fluid 30. Because thegas bubbles 50 are part of the molding surface and the gas bubbles 50often have substantially spherical convex outer surfaces, the hardenedlayer 31 often has substantially spherical concave surfaces. Theconcavities formed in the hardened layer 31 can be micro-concavities.

In the process shown in FIG. 1D, an article (i.e., hardened layer) 31having a plurality of concave surfaces 32 such as a plurality ofmicro-concavities can be obtained by removing or separating the hardenedlayer 31 from the mold 10. In some embodiments, the mold 10 can be usedto form other hardened layers 31. The article 31 having at least oneconcavity can be used as an optical article such as a lens or array oflenses or can be used to prepare a second article that has at least oneconvexity.

In some embodiments of the article 31, a first surface of the articlehas multiple concavities and a second surface opposite the first surfaceis flat. The flat surface can have a matte or glossy finish. The surfaceroughness of either surface can be, for example, less than 100nanometers, less than 50 nanometers, less than 10 nanometers, or lessthan 5 nanometers. The surface roughness can be measured using aprofilometer such as a Surface Profiler System P-16 from KLA-TencorCorporation.

The process shown in FIGS. 1A to 1D can be performed in a continuousmanner to provide articles 31 having at least one concavity such as anarranged pattern of concavities. Any pattern of concavities can beimparted to the article from a molding surface in contact with thehardenable fluid 30. The molding surface includes at least a portion ofat least one gas bubble 50. A concavity in the resulting hardened layeris formed where the outer surface of the at least one gas bubble 50contacts the hardenable fluid 30.

The article 31, manufactured through the processes of the steps of FIG.1A to FIG. 1D, has a surface that is the inverse of the molding surfaceused to form the article. More particularly, the article 31 hasconcavities that were imparted by portions of the outer surface of gasbubbles 50. Often, the shape of concavity 32 is the inversion of asubstantially spherical surface having a curvature determined by thesize of the gas bubbles 50. The concavities can have any suitable sizedepending on the use of the article 31. Some exemplary concavities havea cross-sectional area in the bottom portion that is about 0.01 μm² ormore, 0.1 μm² or more, or 1 μm² or more. This cross-sectional area isoften 100 mm² or less, 10 mm² or less, or 1 mm² or less. The height ofthe concavity 32 is often 0.1 μm or more, 10 μm or more, or 10 μm ormore. This height can be, for example, 100 mm or less, 10 mm or less, or1 mm or less.

FIG. 3A illustrates another manufacturing process corresponding to theprocess shown in FIG. 1D. FIG. 3A shows a process that can be used toobtain an article 31 having a concave surface 32 with an over-hangportion 32A. Over-hang portions can often be formed using a mold thathas depressions with a subulate shape (i.e., depressions having a shapethat tapers to a point) such as triangle pyramid, square pyramid,circular cone, or the like. Additionally, the over-hang portion can havea sharp or pointed edge. Articles with concave surfaces that include anover-hang portion can be easily manufactured; these types of structurescan be very difficult to form using methods such as mechanical machiningor the like.

FIGS. 3A and 1D illustrate how the shape of the depression can beselected to alter the shape of the at least one concavity formed on thesurface of the article. In addition to the shape of the depression 11,other variables can be used to alter the shape of the concavities formedwhen the hardenable fluid 30 is hardened to article 31. That is, themolding surface in contact with the hardenable fluid 30 can be varied byaltering the size and shape of the depressions and other processvariables.

Since the concave surfaces 32 are formed by entrapping gas bubbles 50 inthe respective depressions 11 arranged in the mold 10, a plurality ofconcave surfaces 32 can have substantially the same shape if thedepressions have substantially the same shape. That is, therepeatability of the process of making concave surfaces can becontrolled by controlling the entrapped gas bubbles. More particularly,by controlling the size, shape, and position of the entrapped gasbubbles 50, the size, curvature, and position of the concave surfaces 32can be controlled.

The size (e.g., volume, diameter, or cross-sectional area) of the gasbubbles 50 may be controlled by, for example, (a) adjusting the size andshape of the depressions 11 of the mold 10, (b) adjusting the viscosityof the hardenable fluid 30 that is applied to the mold 10, (c) adjustingthe speed of applying the hardenable fluid 30 to the mold 10, (d)adjusting the interfacial tensions among the hardenable fluid 30, themold 10, and the gas bubbles 50, (e) adjusting the time from coating ofthe hardenable fluid 30 to the hardening thereof, (f) adjusting thetemperature of the gas bubbles 50, and (h) adjusting the pressure to beapplied to the gas bubbles 50. The specific size of the gas bubbles 50adjustable in the above mentioned manner may have, for example, adiameter in the range of 0.1 μm to 100 mm. Each adjustment is furtherdescribed below.

The size and shape of the depressions 11 can be used to adjust the sizeof the gas bubbles 50. The gas bubbles 50 within the depressions 11 aresignificantly influenced by the interfacial tension between the gasbubbles 50 and the hardenable fluid 30 in the region where the gasbubbles 50 contact the hardenable fluid 30. In the vicinity of theregion where the gas bubbles 50 contact the hardenable fluid, the gasbubbles 50 are also influenced by the interfacial tension between thegas bubbles 50 and the mold surfaces of the depressions 11 and theinterfacial tension between the hardenable fluid and the mold surfacesof the depressions 11. The gas bubbles 50 often form smoothsubstantially spherical convex surfaces in the region where the gasbubbles 50 contact the hardenable fluid, while the curvature and shapeof the convex surfaces are influenced by the size and shape of thedepressions 11.

The size and configuration of the depressions 11 affect the curvatureand shape of the gas bubbles 50 whose curvature and shape aresubsequently imparted to the molded articles. While the depressions 11can take various planar shapes, if the resulting concavities will beused as a lens, it is often preferable that the planar shape of thedepressions 11 be a symmetrical shape (point symmetrical or linesymmetrical) or a shape similar to symmetrical shape. That is, when thedepression 11 is arranged in such a way that the vertex of the convexsurface of the gas bubble 50 comes to the center of the approximatelysymmetrical planar shape, the gas bubble 50 can have a smooth convexsurface that has few deformations. As the mold 10 is placedhorizontally, buoyancy and gravity can be uniformly applied to theconvex surfaces so that the gas bubbles 50 can have substantiallyspherical convex surfaces.

The viscosity of the hardenable fluid can be adjusted to control thesize of the gas bubbles 50. For example, in the process schematicallyillustrated in FIG. 1B, the size of the entrapped gas bubbles 50 can becontrolled by adjusting the viscosity of the hardenable fluid 30 that isapplied to the mold 10. Specifically, the size of the gas bubbles 50 canbe increased by increasing the viscosity of the hardenable fluid, whilethe size of the gas bubbles 50 can be decreased by decreasing theviscosity of the hardenable fluid. The viscosity of the hardenable fluidis not limited, but is often 1 mPa-sec or more, 10 mPa-sec or more, or100 mPa-sec or more. The viscosity of the hardenable fluid can be 100000mPa-sec or less, 10000 mPa-sec or less, or 1000 mPas or less. Theadjustment of the viscosity can be carried out by adjusting theconcentration of the hardenable fluid (solvent can be added or removed)or by adding a thickener.

The coating speed can be adjusted to control the size of the gas bubbles50. In the process schematically illustrated in FIG. 1B, the size of thetrapped gas bubbles 50 can be controlled by adjusting the speed ofcoating the hardenable fluid 30 to the mold 10. If the mold isstationary, the speed of moving the coating device 40 can be adjusted.Alternatively, if the coating device 40 is stationary, the speed ofmoving the mold can be adjusted. As exemplified in FIG. 1B, the movementof the coating device 40 is indicated by the arrow A. If a knife coateris used as the coating device 40, the coating speed can be defined bythe speed of the moving the knife edge. Specifically, the size of thegas bubbles 50 can be increased by increasing the coating speed, whilethe size of the gas bubbles 50 can be decreased by decreasing thecoating speed. Although any suitable coating speed can be used, someexemplary coating speeds are in the range of 0.01 to 1000centimeters/second, in the range of 0.5 to 100 centimeters/second, inthe range of 1 to 50 centimeters/second, or in the range of 1 to 25centimeters/second.

In the process shown in FIG. 1B, the size of the entrapped gas bubbles50 can also be controlled by adjusting the interfacial tension betweenthe hardenable fluid 30 and the molding surface of the mold 10, theinterfacial tension between the hardenable fluid 30 and the gas bubbles50, and the interfacial tension between the gas bubbles 50 and thesurface of the mold 10. Specifically, for example, the size of the gasbubbles 50 can be increased by increasing the contact angle between thehardenable fluid 30 and the surface of the mold 10 (decreasing thewettability), while the size of the gas bubbles 50 can be decreased bydecreasing the contact angle between the hardenable fluid 30 and thesurface of the mold 10 (increasing the wettability).

In some cases, the contact angle can be changed by treating the moldingsurface of mold 10. For example, in some cases, the molding surface canbe treated using, for example, a plasma treatment, a vapor treatment, aliquid treatment, or in any other treatment that can change the contactangle. For example, the molding surface can be treated in a plasma thatincludes fluorine or a fluorine-based material. As another example, themolding surface can be treated with a solution of Novec (registeredtrademark) EGC-1720 electronic coating solution available from 3M (St.Paul, Minn.). EGC-1720 is a clear, low viscosity solution of afluorosilane polymer and can, in some cases, increase the contact angle.

In the processes shown in FIGS. 1B and 1C, the size of the entrapped gasbubbles 50 can be controlled by adjusting the time from coating of thehardenable fluid 30 to hardening thereof. Specifically, the size of thegas bubbles 50 can be increased by shortening the time from coating ofthe hardenable fluid 30 to hardening thereof, while the size of the gasbubbles 50 can be decreased by lengthening the time from coating of thehardenable fluid 30 to hardening thereof.

In the processes shown in FIGS. 1B and 1C, the size of the entrapped gasbubbles 50 also can be controlled by adjusting the temperature of thegas bubbles after coating the hardenable fluid 30 but before or duringhardening of the hardenable fluid 30. Specifically, the size of the gasbubbles 50 can be increased by raising the temperature of the gasbubbles 50, while the size of the bubbles 50 can be decreased bylowering the temperature of the gas bubbles 50. The adjustment of thetemperature of the gas bubbles 50 is one of control methods that canchange the size of the bubbles 50 after the gas bubbles 50 areentrapped.

The size of the trapped gas bubbles 50 can be controlled by adjustingthe pressure applied to the gas bubbles 50 after coating the hardenablefluid 30 but before or during hardening of the hardenable fluid 30.Specifically, the size of the gas bubbles 50 can be increased byincreasing the pressure applied to the gas bubbles 50, while the size ofthe gas bubbles 50 can be decreased by decreasing the pressure appliedto the gas bubbles 50. The adjustment of the pressure of the gas bubbles50 another control methods that can change the size of the bubbles 50after the bubbles 50 are trapped.

The positions of the gas bubbles 50 may be controlled, for example, byadjusting the interfacial tension between the liquid resin and themolding surface of the mold 10. The positions can also be controlled byadjusting the viscosity of the liquid resin and the length of time fromcoating of the hardenable fluid to hardening thereof.

In the process shown in FIG. 1B, the gas bubbles 50 should remain at thepositions where the gas bubbles 50 contact the surfaces 12 and 13 of thedepressions 11 until the liquid resin is hardened after the entrapmentof the gas bubbles 50. As shown in FIG. 4, whether the gas bubbles 50remain or not in contact with the mold surface in a depression can beinfluenced by the interfacial tension f1 between the hardenable fluid 30and the mold surface 12 of the mold 10, the interfacial tension f2between the hardenable fluid 30 and the gas bubbles 50, and theinterfacial tension f3 between the gas bubbles 50 and the mold surface12 of the mold 10. The position of the gas bubbles within the depressioncan also be influenced by gravity and buoyancy.

Among those process variables, the positions and shapes of gas bubbles50 can be controlled especially by adjusting the interfacial tension f1between the hardenable fluid and the mold surface 12 of the mold 10.Even if the contact angle between the hardenable fluid 30 and the moldis relatively high, the gas bubbles 50 can remain in the depression 11if the viscosity of the hardenable fluid 30 is sufficiently high.Likewise, even if the contact angle between the hardenable fluid 30 andthe mold is relatively high, when the hardenable fluid 30 is hardenedrapidly (e.g., a UV curable resin can be irradiated with high intensityUV radiation very soon after coating), the gas bubbles 50 can remain inposition long enough to function as part of the molding surface and canimpart their shape to the resulting hardened layer.

Any other means known in the art for controlling the shape of the gasbubbles can be used. For example, means such as gravity,electromagnetism, or vibration (including ultrasonic vibration) can beused to control the shape of the gas bubbles.

In another aspect, a method is provided for preparing a second articlehaving at least one convexity from the article having at least oneconcavity. The article having at least one concavity is used as a mold(second mold) to form the second article. FIGS. 1E to 1G illustrate oneembodiment of a manufacturing method for the second article. In thisembodiment, an article 31 manufactured as shown in FIG. 1A to 1D can beused as the second mold. A second hardenable fluid 60 is applied to thesecond mold 31 and hardened to form a second article 61 having aplurality of convex surfaces 62. FIGS. 1E to 1G are schematic sectionalviews illustrating the individual manufacturing processes to manufacturethe second article 61 having a plurality of convex surfaces 62.

Like the manufacturing process shown schematically in FIGS. 1A to 1D,the manufacturing processes shown in FIG. 1E to 1G can also carried outin air. In FIG. 1E, a second mold 31 having a plurality of concavesurfaces 32 is provided. In FIG. 1F, a second hardenable fluid 60 isapplied to the second mold 31. The second hardenable fluid 60 ishardened to a second hardened layer 61. In FIG. 1G, the second hardenedlayer 61 is removed from the second mold 31 to obtain a second articlehaving a plurality of convex surfaces 62. The shape of the convexities62 correspond to the shape of the gas bubbles 50 used to impart theconcavities to the second mold 31.

In FIG. 1E, the second mold (first article) 31 is provided that can bemanufactured using the processes schematically illustrated in FIGS. 1Ato 1D. In some embodiments, second mold 31 is prepared from a hardenablefluid 30 that is selected, for example, from a UV curable resin, solubleresin, thermoplastic resin, thermoset resin, or the like. Any of thehardenable fluids described above can be hardened to from the secondmold 31.

In FIG. 1F, a second hardenable fluid 60 is applied to the second mold31. Although any suitable application method can be used, the hardenablefluid 60 is often applied to the second mold 31 using a coating process.In contrast to the process schematically illustrated in FIG. 1B,however, gas bubbles are typically not deliberately entrapped during theprocess shown in FIG. 1F. Methods that may be difficult to use in theprocess of FIG. 1B can be used in the process of FIG. 1F. For example,processes such as injection, heat pressing, or electroforming can beused for applying the second hardenable fluid 60 to the second mold 31.

The second hardenable fluid 60 can be any material that is describedabove for use as the hardenable fluid 30. In some examples, the secondhardenable fluid 60 can be selected to be a UV curable resin or asoluble resin. When the second mold 31 has sufficient heat resistance, athermoplastic resin or a thermoset resin can also be used for the secondhardenable fluid 60. The second hardenable fluid 60 can contain anadditive such as, for example, a thickener, a curing agent, acrosslinking agent, an initiator, an oxidant inhibitor, an antistaticagent, a diluent, a detergent, a pigment, or a dye.

In some applications such as those where the at least one convexity willbe used as a lens, the second hardenable fluid 60 is a polymeric resinthat will result in the formation of a hardened layer that has goodoptical properties. For example, the polymeric resin can be a polymericresin that includes polycarbonate, acrylic resin, polyester, epoxyresin, polyurethane, polyamide, polyolefin, or silicone (includingmodified silicone such as silicone polyurea, or similar material.

The hardenable fluid 60 is often applied to the second mold 31 using acoating method although other suitable application methods can be used.Suitable coating devices include, but are not limited to, a knifecoater, a bar coater, a blade coater, and a roll coater. If the coatingmethod is used, a deaeration process can be added before or aftercoating the second hardenable fluid 60 to remove any bubbles or air thatmight cause defects in the second article. Suitable deaeration processesoften include an evacuation step. The deaeration process can oftenremove bubbles or air in the second hardenable fluid 60 or positionedbetween the second hardenable fluid 60 and the second mold 31.

The second hardenable fluid 60 is hardened to form the second hardenedlayer 61. When the second hardenable fluid is a UV curable resin, thesecond hardened layer 61 can be formed by irradiating with ultravioletrays. When the second hardenable fluid 60 is a solution of a solubleresin, the second hardened layer 61 can be formed by removing thesolvent such as by drying. When the second hardenable fluid 60 is athermoplastic resin, the second hardened layer 61 can be formed bycooling the resin down to at least a softening temperature. When thesecond hardenable fluid 60 is a thermoset resin, the second hardenedlayer 61 can be formed by heating the resin to at least a hardeningtemperature.

Through the process shown in FIG. 1F, the second hardened layer 61having a plurality of convex surfaces 62 can be formed. The convexsurfaces 62 are the inversion of the outer shapes of the concavesurfaces 32 of the second mold 31. Specifically, the convex surfaces 62formed on the second hardened layer 61 can be substantially sphericalconvex surfaces that are similar to the outer shapes of the gas bubbles50 used to impart the concavities to the second mold 31. Thus, a secondarticle having at least one substantially spherical convex surfaces suchas an arranged pattern of substantially spherical convex surfaces can beprepared.

In some embodiments of the article 61, a first surface of the articlehas multiple convexities and a second surface opposite the first surfaceis flat. The flat surface can have a matte or glossy finish. The surfaceroughness of either surface can be, for example, less than 100nanometers, less than 50 nanometers, less than 10 nanometers, or lessthan 5 nanometers.

In the process shown in FIG. 1G, a second article 61 having a pluralityof convex surfaces 62 can be obtained by removing the hardened layer 61formed in the process shown in FIG. 1F from the second mold 31. It isalso possible to coat another resin material or the like on the convexsurfaces 62 of the manufactured second article 61.

The second article can be prepared using a continuous manufacturingprocess. By repeatedly providing additional second molds 31 to a coatingdevice, the second hardenable fluid 60 can be repeatedly applied to eachadditional second mold 31. Each additional hardenable fluid 60 can behardened to form second articles 61 having at least one convexity. Byrepeating the processes shown in FIG. 1A to 1D and the processes shownin FIG. 1E to 1G, articles 31 each having a plurality of concavesurfaces 32 and second articles 61 each having a plurality of convexsurfaces 62 can be manufactured continuously.

Similar processes to those shown in FIGS. 1A to 1G can be used toprovide articles having at least one convexity on a first surface aswell as on a second surface opposite the first surface. In one suchprocess, the second article can be prepared that has at least oneconvexity. A third article can then be prepared by contacting the secondarticle with a hardenable fluid layer. For example, the finished secondarticle can be laminated to the hardenable fluid layer 60 shown in FIG.1F. That is, a hardenable fluid layer 60 can be positioned between afinished second article and the second mold. When the hardenable fluidlayer 60 is hardened, the second article would adhere and the resultingthird article can have convexities on two opposite surfaces. The secondmold could then be removed to provide the third article. In anotherprocess, two finished second articles can be laminated using a hardenedfluid layer 60 positioned between the two second articles. The hardenedfluid layer would face a flat surface of the two second articles.

Alternatively, a hardenable fluid layer can be positioned between twosecond molds 31. The hardenable fluid layer would face a flat surface ofthe two second molds. Upon hardening of the hardenable fluid layer, theresulting third article would have concavities on two opposite surfaces.

An adhesive layer can be positioned between a first article and a secondarticle, between a first article and another first article, or between asecond article and another second article to provide articles havingconcavities or convexities on multiple surfaces. In these embodiments,the adhesive layer would face a flat surface of the first article and aflat surface of the second article.

Regarding the process shown in FIG. 1F and FIG. 1G, other conventionalmolding process can be used. For example, molding process described inU.S. Pat. No. 6,761,607 or U.S. Pat. No. 6,758,992 can be used.

FIG. 3B shows a process similar to the process shown in FIG. 1G. FIG. 3Billustrates an exemplary process that can be used to obtain a secondarticle 61 having convex surfaces 62 by removing a second hardened layer61 from the second mold 31 that has concavities 32 with a sharper edgedoverhang portion 32 a in comparison to the corresponding concavitiesshown in FIG. 1G. If both the second mold 31 and the second hardenedlayer 61 are both hard in the process exemplified in FIG. 3B, it can bedifficult to separate the second mold 31 without damaging the hardenedlayer 61.

A removal process that damages the hardened layer 61 is depicted as case1 in the sectional views of FIGS. 6A and 6B. The second mold in FIG. 6Ais made of a material that is not readily soluble in water or an organicsolvent. When the hardened layer 61 is removed from the second mold 31,the hardened layer 61 interferes with the overhang portion 32 a of thesecond mold 31. If the hardened layer 61 and the second mold 31 are bothare hard and not flexible, damage is likely. FIG. 6B illustrates thatthe hardened layer 61 and the second mold 31 can both be damaged. Theoverhang portion 32 b is broken off of the second mold 31.

One method of removing the hardened layer 61 from the second mold 31without damaging the hardened layer 61 is depicted as case 2 in thesectional views of FIGS. 6C and 6D for case 2. In FIG. 6C, the secondmold is formed of a soluble material such as water-soluble resin. InFIG. 6D, the second mold is removed by dissolution. Since the secondmold 31 is dissolved by water, the hardened coating layer 61 is removedundamaged from the second mold 31. Although the second mold 31 in FIG.6C is a water-soluble resin, a similar process can be used with anyother mold materials that can be dissolved with another type of solventsuch as an organic solvent or a solution containing an acid or base.

In other examples, the second mold 31 can be readily separated from thehardened layer 61 when a thermoset resin is used for the hardened layer61 and a thermoplastic resin is used for the second mold 31. The secondmold can be heated to at least the softening temperature to remove itreadily from the hardened layer 61 without damaging the hardened layer61.

The manufactured second article 61 is an article having at least oneconvex surface 62. Some second articles have an arranged pattern ofconvexities such as a lattice pattern. The convex surfaces 62 are oftensubstantially spherical convex surfaces that correspond to the outersurfaces of the gas bubbles 50 used to form the concavities in thesecond mold 31. The size of the convex surface 62, as measured by thecross-sectional area of the base, is often in the range of 0.01 μm² to1000 mm². The height of the convex surface 62 often ranges from 0.1 μmto 100 mm. Convexities outside this range can also be prepared and thesize is dependent on the particular use chosen for the articles.

In some second articles 61, there is a plurality of convexities arrangedin a pattern. Some arranged patterns are arranged in lattice patternssuch as an arranged square lattice pattern. Additionally some of thearticles have substantially identical convex surfaces 62. When theconvex surfaces 62 are spherical and substantially transparent ortranslucent, they can be used as lenses or an array of lenses. Some ofthe convexities 62 can be used as microlenses or microlens arrays.

Additionally, the second article 61 can have another layer of materialcoated on the convex surfaces 62. In this case, if the convex surfaces62 are used as lenses, the coating layer can be used as a protectinglayer or can be used to adjust the refractive index. A lens having awide range of refractive indexes can be obtained by coating materialshaving various refractive indexes as the outermost layer of the lens.

When forming a second article 61 using a first article 31 as a mold, thefirst article 31 need not be removed from the second article 61. Thatis, the first article 31 can remain adjacent to the second article 61;for example, the second article 61 can be laminated to the first article31. Another single coating layer or multiple coating layers can beformed on the second article 61. In this case, the first article 31remaining on the second article 61 or any additional coating layer canbe used as a protecting layer for the second article 61, or as a layerfor adjusting the optical characteristics of the second article 61.

As shown in the FIG. 1G, the manufactured second article 61 can have ashape in which each convex surface 62 is surrounded by a horizontal wall63 because the second mold 31 has a shape in which each concave surface32 is surrounded by a groove-like portion 33. Because the shape of thesecond article 61 is the inversion of the article 31, the second article61 has horizontal walls 63 corresponding to the groove-like portions 33of the second mold 31. See FIG. 8 schematically showing an exemplarythree-dimensional article 131 and FIG. 9 showing an exemplarythree-dimensional article 161. One way to handle the second article 61having a shape in which each convex surface 62 is surrounded by thehorizontal wall 63 is to positively utilize the horizontal walls 63 asoptical components such as prisms. Two exemplary such articles are shownin FIGS. 18A and 18B. FIG. 18A is a schematic cross-section of anarticle 1850 that includes a structured top surface and a planar or flatbottom surface. The top structured surface includes a plurality ofconvexities 1810 and a plurality of prisms 1820 pointing outward,meaning that the apex of each prism points away from the bottom surface.In the exemplary article 1850, convexities 1810 and prisms 1820alternate. In general, the prisms and the convexities may or may form analternate arrangement.

FIG. 18B is a schematic cross-section of an article 1860 that includes astructured top surface and a planar or flat bottom surface. The topstructured surface includes a plurality of concavities 1830 and aplurality of prisms 1840 pointing inward, meaning that the apex of eachprism points toward the bottom surface. In the exemplary article 1860,concavities 1810 and prisms 1820 alternate. In general, the prisms andthe concavities may or may form an alternate arrangement.

In FIGS. 18A and 18B, the top structured surface of articles 1850 and1860 includes a lattice pattern of concavities 1830 or convexities 1810and a lattice pattern of prisms 1820 or prisms 1840. In some cases,concavities 1830 or convexities 1810 are or include spherical orsubstantially spherical surfaces. In some cases, concavities 1830 havethe same shape and convexities 1810 have the same shape. In some cases,concavities 1830 have the same size and convexities 1810 have the samesize.

In some cases, such as when articles 1850 and 1860 are being formedusing, for example, process steps shown in FIGS. 1A through 1G,concavities 1830 or convexities 1810 are in direct contact with gasbubbles, such as with gas bubbles 50.

In some cases, such as when the top structured surfaces of articles 1850and 1860 are molding surfaces, concavities 1830 or convexities 1810 arein direct contact with a hardenable fluid before the fluid is cured,such as layer 30 in FIG. 1B, or in direct contact with a hardened fluid,such as layer 31 in FIG. 1C.

In some cases, articles 1850 and 1860 can be optical films and can beused in a display system such as a liquid crystal based display system.In such cases, optical films 1850 and 1860 can be substantiallyoptically transparent. For example, in such cases, the total (specularand diffuse) optical transmission of optical films 1850 and 1860 is atleast 70%, or at least 80%, or at least 90%. In some cases, opticalfilms 1850 and 1860 can be optical gain diffusers in a liquid crystalbased display system. In such cases, concavities 1830, convexities 1810,prisms 1820, and prisms 1840 can diffuse and/or redirect the lightresulting in increased brightness along a preferred, such as axial,direction and/or increased diffusion that can result in increasedviewing angle and/or improved light intensity uniformity.

In other embodiments, the second article 61 does not have horizontalwalls 63 between the convexities 62. The horizontal walls 63 can beremoved from the manufactured second article 61 by a post-processing. Ifthe horizontal walls 63 are formed but not desired, they can be removedusing any suitable mechanical, physical, or chemical means. When thesecond article 61 having the convex surfaces 62 is adapted to a lensmember, for example, it is possible to provide microlenses in which lensportions having spherical surfaces are arranged on a sheet by removingthe horizontal wall 63 formed between the adjacent convex surfaces 62 ofthe second article 61. Additionally, the curvature can also be alteredby further processing the curved surface portions of the convex surfaces62. An article could be manufactured in which partly-cutaway convexsurfaces are formed by cutting off a given portion of each of aplurality of convex surfaces 62.

Alternatively, the second article can be prepared using a mold that doesnot result in the formation of the horizontal walls 63. Moreparticularly, the groove-like portion can be eliminated between adjacentconcave surfaces of the second mold. One such second mold 31 can bemanufactured, for example, as illustrated schematically in FIGS. 7A to7D. The second article 161 having a shape in which each convex surface162 is not surrounded by a wall is manufactured as shown in FIG. 7E to7G. FIG. 11 shows a three-dimensional example corresponding to thearticle 131′A and FIG. 12 showing a three-dimensional corresponding tothe second mold 161.

The manufacturing processes shown in FIGS. 7A to 7D are similar to theprocesses shown in FIGS. 1A to 1D; however, a two piece mold is usedrather than a one piece mold. The first piece of the mold is a firstlayer having at least one opening such as a pattern of openings. Thesecond piece of the mold is laminate to the first layer. The resultingtwo piece mold can have depressions consisting of the opening of thefirst layer and a surface of the second layer.

The two piece mold 110 of FIG. 7A has a side wall portion 110 acorresponding to the first layer mentioned above and a bottom portion110 b corresponding to the second layer mentioned above. The first layerand the second layer are separable each other, and as a result, as shownin FIG. 7D, the side wall portion 110 a can be removed from the bottomportion 110 b along with hardened layer 131.

The two piece mold 110 can be prepared from any materials describedabove for the mold 10. For example, an organic resin material such aspolyimide, polypropyrene, polyethylene, polystyrene or poly-cyclo-olefincan be used. Alternatively, other organic materials, inorganic materialsincluding a metal such as nickel, copper, or brass, glass or ceramics,or organic-inorganic composite material can be used. Preferably, amaterial chosen for the side wall portion 110 a (first layer) isdifferent from a material chosen for the bottom portion 110 b (secondlayer). For example, an organic resin material can be used for the sidewall portion 110 a, and an inorganic material such as metal, glass orceramic can be used for the bottom portion 110 b.

The two piece mold can be made by the following process. First, alayered sheet having a first layer and a second layer laminated on thefirst layer can be prepared. Then openings can be formed in the firstlayer using any suitable method. In some methods of forming the opening,a dry etching method such as laser ablation or a wet etching methodusing a mask can be used. If the first layer material is different fromthe second layer material, the opening patterns can be formed only inthe first layer.

Suitable layered sheets are commercially available but can also bemanufactured by the following process. The first layer can be preparedand then the second layer can be provided to contact the first layer.The second layer can be formed on the first layer using any methodincluding, for example, coating, deposition, electroforming or the like.For example, a polymeric resin sheet can prepared as the first layer.Then second layer can be formed on the first layer by chemicaldeposition, physical deposition, or electroforming a metal.

In the process shown in FIG. 7D, the hardened layer 131, which is formedby the process shown in FIG. 7C, and the side wall portion 110 a areremoved from the bottom portion 110 b of the mold 110. Upon removal fromthe bottom portion 110 b of the mold, the hardened layer 131 and theside wall portion 110 a are connected together to obtain an article131′. The article 131′ is configured so that each concave surface 132 issurrounded by the side wall portion 110 a. In other words, anygrove-like portion does not exist between adjacent concave surfaces 132.

The removing process shown in FIG. 7D can be performed by selectiveetching of the bottom portion 110 b of the mold 110. For example, if thebottom portion 110 b is made of metal such as copper or nickel and theside wall portions 110 a are made of polymeric resin such as polyimide,the bottom portion 110 b can be removed by such a selective etching. Forexample, the metal can be dissolved with an acidic solution.

Manufacturing processes shown in FIGS. 7E to 7G are similar to theprocesses shown in FIGS. 1E to 1G. However, a second article 161 ismanufactured using the second mold 131′ having a shape in which anygrove-like portion does not exist between adjacent concave surfaces 132.As a result, as shown in FIG. 7G, a second article 161 having a shape inwhich each convex surface 162 is not surrounded by a horizontal wall ismanufactured. In the other points, the processes shown in FIG. 7E to 7Gare similar to the processes shown in FIG. 1E to 1G.

The second article 161 in which each convex surface 162 is notsurrounded by a horizontal wall can be obtained by using the second mold131′ in which a groove like portion does not exist between adjacentconcave surfaces 132. When the second article 161 having the convexsurfaces 162 not surrounded by horizontal walls is adapted to a lensmember, for example, the second article has a construction without aprism or rib portion. Such an article is well suited for a lens such asa microlens because there is no horizontal wall between adjacent convexsurfaces 162 (equivalent to lens portion) of the second article 161. SeeFIG. 13 for a three-dimensional representation of the second mold 131′Band FIG. 14 for a three-dimensional representation of the second article161B.

In addition to the use of the first article or the second article as alens or as an array of lenses, the first article or the second articlecan be used as a mold. For example, the first article or the secondarticle can be used to prepare a metal stamper. In one exemplaryprocess, the first metal layer such as chromium or copper can bedeposited on a surface of the first article or on a surface of thesecond article. Then, a second metal layer such as a nickel metal layercan be deposited on the first metal layer. The second metal layer canthen be removed resulting in a second metal stamper such as a nickelmetal stamper that has the same shape as the first article or the secondarticle.

The embodiments of the method of making a first article that has asurface comprising at least one concavity or an arranged pattern ofconcavities, the method of making a second article using the firstarticle as a second mold, the first article, and the second article arenot limited to those described above, and various other embodiments arewithin the scope of the invention.

EXAMPLES

These examples are for illustrative purposes and are not meant to belimiting on the scope of the appended claims. Examples of the first andsecond articles were manufactured and tested. These examples aredescribed referring to the accompanying drawings.

Examples 1-1 to 1-9

The influence of the interfacial tension between the hardenable fluidand a mold surface were investigated. Nine kinds of test plates withflat surfaces were prepared and the contact angles of the hardenablefluid (e.g., liquid resin) on the flat surfaces of the test plates weremeasured. Further, test articles were manufactured using nine kinds oftest molds that were made of the same materials of the test moldsrespectively according to the manufacturing process shown in FIG. 1A toFIG. 1D.

Liquid Resin: A UV curable resin was used as the hardenable fluid. Thecomposition of the UV curable resin contained 90 parts by weight (pbw)of a UV hardenable acrylate, which was a polyester base urethaneacrylate (commercially available under the trade designation EBECRYL8402 from DAICEL-CYTEC Co., Ltd.), 10 pbw of an unsaturated aliphaticacid hydroxylalkylester modifier ε-carprolactone (commercially availableunder the trade designation PLACEL FA2D from Daicel Chemical Industries,Ltd.), and 1 pbw of a photopolymerization initiator (commerciallyavailable under the trade designation IRGACURE 2959 from Ciba SpecialtyChemicals Inc.).Test Plates: Each of the nine test plates had a flat surface. Materialsused for the test plates are described below.

Test Molds: All test molds had depressions in the shape of aquadrangular pyramid having a depth of 50 μm, an apex angle of 90degree, and a square bottom shape. Each side of the square bottom was100 μm. The depressions were arranged in a square lattice pattern withpitches of 100 μm. Materials used for the test molds are describedbelow.

Materials for the Test Plates and the Test Molds:

Test Plate 1 and Test Mold 1 were prepared from a two component roomtemperature vulcanizable (RTV) silicon rubber, which is commerciallyavailable under the trade designation ELASTOSIL RT 601 from WackerAsahikasei Silicone Co., Ltd.

Test Plate 2 and Test Mold 2 were prepared from a two component RTVsilicon rubber, which is commercially available under the tradedesignation ELASTOSIL M4470 from Wacker Asahikasei Silicone Co., Ltd.

Test Plate 3 and Test Mold 3 were prepared from polypropylene, which iscommercially available under the trade designation NOVATEC MA-3 fromJapan Polypropylene Co., Ltd.

Test Plate 4 and Test Mold 4 were prepared from polystyrene, which iscommercially available under the trade designation GPPS G9401 from JapanPolystyrene Inc.

Test Plate 5 and Test Mold 5 were prepared from polyethylene, which iscommercially available under the trade designation HY-430 from JapanPolyethylene Co., Ltd.

Test Plate 6 and Test Mold 6 were prepared from polycarbonate, which iscommercially available under the trade designation IUPILON H-3000R fromMitsubishi Engineering-Plastics Co., Ltd.

Test Plate 7 and Test Mold 7 were prepared from polypropylene, which iscommercially available under the trade designation POLYPRO3445 fromExxon Mobil Co.

Test Plate 8 and Test Mold 8 were prepared from polymethylmethacrylate,which is commercially available under the trade designation LG35 fromSumitomo Chemical Co., Ltd.

Test Plate 9 and Test Mold 9 were prepared from nickel plate that wasmanufactured using electroforming.

The hardenable fluid, which was the UV curable resin, was coated on asurface of each test mold using a knife coater to form a coated layer.The coating device was a knife coater with a 150 mm width. A PET filmwas positioned over the UV curable resin such that the UV curable resinwas between the test plate and the PET film. The coating thickness ofthe UV curable resin was 150 μm. The coated layer was cured aftercoating using ultraviolet radiation of 3450 mJ/cm² from a UV lampobtained from Ushio, Inc. The hardened resin was then removed from thetest mold.

TABLE 1 Contact Angle [degree] of Liquid Article made Resin on TestPlate using Test Test Plate No. and (Average of 10 Mold shown ExampleTest Mold No. samples) in FIG. 5 1-1 1 63.4 A 1-2 2 60.9 A 1-3 3 59.5 B1-4 4 41 C 1-5 5 57.3 C 1-6 6 34.5 C 1-7 7 64 B 1-8 8 33.4 C 1-9 9 38.2C

Under the above test conditions, the contact angle between the UV resinand the mold was changed by changing the material of the test plate. Therelationship between the contact angle (between the UV resin and thetest plate) and the position and shape of the gas bubble 50 entrapped inthe test mold depressions were studied. Table 1 shows the average valuesof the measured values of the contact angle between the liquid resin (UVcurable resin) and the test plates. The average values of tenmeasurements are given in Table 1.

The static contact angles were measured using an instrument commerciallyavailable under the trade designation DROPMASTER 700 from KyowaInterface Co., Ltd., and the static contact angle was measured by thesessile drop method at room temperature.

FIG. 5 is a diagram exemplifying the relationship between the contactangle and the position and the shape of the gas bubbles within the molddepressions. More particularly, FIG. 5 shows three representative typesA to C of the concavities made by the manufacturing process using thetest molds. In FIG. 5, a perspective view (left), a side sectional view(center), and a plane view (right) of the articles manufactured.

Articles made using Test Molds 1 and 2, corresponding to a contact anglegreater than 60 degree, were Type A where the gas bubbles do not stay inthe depressions. That is, no gas bubbles remained in the depressions.Articles made using Test Molds 3 and 7 were Type B. The gas bubblesremained at the top portions of the quadrangular pyramid depressions andthe curvature of the convex surfaces of the gas bubbles were relativelysmall (the diameters were relatively large). The outer shape of the gasbubbles was approximately spherical as seen from the top or bottom sideof the quadrangular pyramid. Articles made using Test molds 4-6, 8 and9, were Type C. The gas bubbles remained at the top portions of thequadrangular pyramid depressions and the curvature of the convexsurfaces of the gas bubbles were larger than for Type B (the diameter issmaller than for Type B). The outer shape of the gas bubbles becamenearly a four-leaved shape as seen from the top or bottom side of thequadrangular pyramid.

According the test result, the positions and shapes of the gas bubblescould be at least partially controlled by adjusting the interfacialtension (contact angle) between the UV resin and the mold surface.Various other variables such as the viscosity of the UV resin and thetime from coating to hardening of the UV resin can also affect theposition and shape of the gas bubbles. For example, even if the contactangle between the UV resin and the mold exceeds 60 degrees, gas bubblescan remain in the depressions if the viscosity of the UV resin issufficiently high. Likewise, even if the contact angle between theliquid resin and the mold exceeds 60 degrees, when the UV resin ishardened by high-intensity ultraviolet irradiation in a short period oftime after coating, the gas bubbles can remain for a time sufficient forthe UV resin to harden.

Example 1-10

In this example, the mold material was cyclic olefin copolymer (COC)8007F-04 obtained from Polyplastics Co. (Frankfurt, Germany). The mold(COC-1) was treated with EGC-1720 and dried in an oven at 60 degrees for30 minutes. The dried mold COC-1 was kept at room temperature overnightfor being used. For comparison purposes, a similarly prepared butuntreated mold (COC-2) was also used. The COC-1 and COC-2 molds had thesame shape similar to the shape of the molds used in examples 1-1through 1-9. In particular, each mold had depressions in the shape of aquadrangular pyramid having a depth of 50 μm, an apex angle of 90degree, and a square shaped bottom. Each side of the square bottom was100 μm. The depressions were arranged in a two-dimensional latticepattern with a pitch of 100 μm along the rows and the columns.

Using the DROPMASTER 700 instrument, the measured static contact angleof deionized water on COC-1 and COC-2 were 105 and 87.2 degrees,respectively. Next, each mold was coated with the UV resin using acoating knife with a coating gap of 150 microns at a coating speed of 16cm/sec. The UV resin coatings were subsequently cured using UV radiationat 3450 mJ/cm2. After curing, the cured samples were removed from themolds resulting in samples COC-A and COC-B corresponding to molds COC-1and COC-2, respectively. FIGS. 15A and 15B are scanning electronmicrographs of samples COC-A and COC-B, respectively. The convexities insample COC-A have a larger radius of curvature than those in sampleCOC-B.

Example 2-1

In Example 2-1, a polypropylene mold was prepared. Initially,depressions were made on a surface of the copper plate using a cuttingmachine. Then a surface of the copper plate was oxidized by dipping thecopper plate in an oxidizing agent. A nickel layer was formed on theoxidized surface of the copper plate by electroplating. Afterelectroplating, the nickel layer was removed from the copper plate.Polypropylene, which is commercially available under the tradedesignation POLYPRO3445 from Exxon Mobil Co., was melted into the nickelmold at 200 to 250° C. and then was cooled down to room temperature (20to 25° C.). The hardened polypropylene mold was removed from the nickelmold. The resulting mold (sheet) had a square lattice pattern ofdepressions. The depressions were quadrangular pyramid concavities thathad a depth of 50 μm, an apex angle of 90 degrees, and a square bottomshape. Each side of the square bottom was 100 μm and the pyramids werearranged at pitches of 100 μm. The shape of the quadrangular pyramiddepressions is exemplified in a planar view in FIG. 2A.

The polypropylene mold (sheet) was cut to make a piece (8 cm in widthand 10 cm in length) that was adhered onto a polyethylene terephthalate(PET) film having a thickness of 50 μm (15 cm in width and 30 cm inlength) to make a sheet mold. The PET film is commercially availableunder the trade designation “TEIJIN TETRON FILM A31 from Teijin DuponFilms Japan Limited. The polypropylene mold (sheet) was adhered to thePET film using double-faced adhesive tape that is commercially availablefrom 3M under the trade designation 3M SCOTCH TAPE.

Another PET film having a thickness of several ten μm (15 cm in widthand 30 cm in length) was prepared as a transparent cover sheet. The PETfilm was the same as described above.

Around 10 cc of the UV curable resin was dropped on a surface of thesheet mold, wherein the UV curable resin was provided along one side ofthe area having the depressions. The UV curable resin used in thisexample is the same as the UV Resin used in Example 1 and the viscositythereof was about 10,000 mPas (measured by B-type viscometer).

One side of the cover sheet was laid on the sheet mold, however, therest of the cover sheet was kept apart from the sheet mold. Next, theone side of the set of the sheet mold and the cover sheet (“set of thesheets”) was placed on a knife coater having a knife edge that is 150 mmwide. The set of sheets was then moved under the knife edge at the speedof 16 cm/sec (“coating speed”) and the UV curable resin was spreadbetween the sheets at the thickness of 200 μm and coated over thedepressions of the sheet mold while air around the mold was entrapped ateach depressions. The coating process was carried out in the air at roomtemperature (about 20-25 degree C.).

Then, a ultraviolet light (Ushio Inc.) was used to irradiate the UVcurable resin on the mold sheet through the transparent PET cover sheetwith ultraviolet rays of 3450 mJ/cm². The radiant intensity was measuredat the surface of the UV resin layer using an ultraviolet light meter(UV-350 from ORC Manufacturing Co., Ltd.). The UV curable resinpolymerized and formed a hardened layer. After polymerization, thetransparent PET cover sheet was taken off the mold sheet. The hardenedlayer was removed from the polypropylene mold by hand. In this manner,an article having concave surfaces (an article having an arrangedlattice pattern of concavities) was obtained from the UV curable resin.

Example 2-2

The hardenable fluid contained 20 weight percent polyvinyl alcohol as awater-soluble resin (commercially available under the trade designationKURARY POVAL PVA-217 from Kurary Co., Ltd.) and 80 weight percentdistilled water. That is, the hardenable fluid contained 20 weightpercent PVA-217 in an aqueous mixture. Using the article having concavesurfaces manufactured in Example 2-1 as the second mold, the hardenablefluid was dropped onto the second mold to cover the concavities and thena deaeration process was used to prevent the formation of bubbledefects. The atmospheric pressure was reduced to less than 1000 Pa for15 minutes. After deaeration, the hardenable fluid was spread and set ata thickness of 200 micrometer using the knife coater. Then, the hardenedlayer was obtained by drying the coating layer for two hours in an ovenat 60 degree C. and was then overnight at room temperature. Afterdrying, the hardened layer was removed from the second mold. Theresulting article made of a polyvinyl alcohol resin had convex surfaces(the article had an arranged lattice pattern of convexities).

Example 2-3

Using a manufacturing method similar to that used in Example 2-1,articles having concave surfaces were obtained by varying the time fromcoating of the UV curable resin to hardening thereof. The start time ofhardening, which is the length of time between coating and hardening,was 0 minute, 30 minutes, or 60 minutes. During any time between coatingand hardening, the samples were stored under ambient light.

The resulting articles having concave surfaces were imaged using ascanning electron microscope (SEM) (VE-7800, Keyence Co., Ltd); theimage obtained is hereinafter called a “SEM image”. In the SEM image ofthe concave surface portions observed substantially vertically above,the maximum diameters of the concave surface portions were measured atfive positions. The average value of the measurements was determined tobe the average diameter of the concave surfaces.

The following Table 2 shows the relationship between the time fromcoating to hardening and the average diameter of the concave surfacesfor this example.

TABLE 2 Time from UV Drying coating to curable temperature,Concentration, Viscosity, hardening, Ave. diameter, resin ° C. weightpercent mPa-sec min. micrometers PVA-217 60 20 60000 0 78.7 30 78.4 6078.0

Example 2-4

An article was prepared as described in Example 2-1 except that the moldwas varied. More particularly, a nickel mold was used and the shape ofthe depressions provided in the mold was changed to a square cylinderfrom a quadrangular pyramid. The square cylinders each had a squarebottom shape with each side of the square being 115 μm. The depressionswere arranged in a square lattice pattern at pitches of 140 μm. Thisnickel mold was prepared from a copper plate. Depressions were made on asurface of the copper plate using a cutting machine. Then a surface ofthe copper plate was oxidized by dipping the copper plate in anoxidizing agent. Then, a nickel layer was formed on the oxidized surfaceof the copper plate by electroplating. After electroplating, the nickellayer was removed from the copper plate.

FIG. 8 shows a perspective view of the article 31A obtained that hadconcave surfaces 32A. The article 31A had an arranged pattern ofconcavities. Each concave surface has a substantially the same shape,and was surrounded by a groove-like portion.

An article having convex surfaces was obtained using the obtainedarticle 31A having concave surfaces as the second mold under the sameconditions as those of Example 2-2. FIG. 9 shows a perspective view ofthe obtained article 61A having convex surfaces 62A (article having anarranged pattern of convexities). Each convex surface has asubstantially the same shape, and is surrounded by a wall 63A.

Article 61A in FIG. 9 includes a plurality of convexities 62A. Eachconvexity 62A is surrounded by walls 63A. Convexities 62A are arrangedat predetermined positions and form a lattice pattern. In some cases,walls 63A can have prism portions positioned, for example, on top of thewalls, resulting in an article similar to article 1850 shown in FIG.18A. In some cases, such as when article 61A is made using the processsteps shown in FIG. 1C, article 61A can be or include a hardened fluid.

In the exemplary article 61A, the curved portions are convexitiessurrounded by walls. In some cases, an article, such as article 31 inFIG. 1D or article 1860 in FIG. 18B, can include a plurality ofconcavities where each concavity is surrounded by grooves, such asgrooves 33 in FIG. 1D or grooves 1840 in FIG. 18B. In some cases, suchas in the case of article 1860, the concavities are arranged atpredetermined positions and form a lattice pattern. In some cases, suchas in the case of article 1860, the concavities are surrounded bygrooves that are or include prism portions. In some cases, such as whenarticle 1860 is made using the process steps outlined in FIG. 1A-1G, thearticle 1860 can be or include a hardened fluid.

Example 2-5

An article having concave surfaces was prepared using a process similarto that used to prepare Example 2-1 except with a different mold. Thedepressions in the mold were changed to a quadrangular prismoid from aquadrangular pyramid. The material of mold was a silicone resin sheetmade of ELASTSIL M4470 from Wacker Asahikasei Silicone Co., Ltd. Thequadrangular prismoid depressions each had a square bottom shape witheach side of the square bottom being 25 μm and a square top shape witheach side of the square top being 50 μm. The depressions were arrangedin a square lattice pattern with pitches of 50 μm. An article havingconcave surfaces (an article having an arranged lattice pattern ofconcavities) was manufactured.

This article was then used as a secondary mold under conditions similarto those used in Example 2-2 except that the second hardenable resin wasdifferent. For this example, a 15 weight percent polyvinyl alcohol as awater-soluble resin (KURARY POVAL™ PVA-205, Kurary Co., Ltd.) and 85weight percent distilled water were mixed. This 15 weight percentPVA-205 aqueous mixture was coated on the second mold. An article madeof a polyvinyl alcohol resin having convex surfaces (an article havingan arranged pattern of convexities) was prepared.

Comparative Example 1

An article was obtained by performing processes similar to those ofExample 2-1 except that after coating of the UV curable resin, the UVcurable resin was left under vacuum for 15 minutes to remove gas bubblesentrapped at the time of coating. The outer shapes of gas bubbles werenot imparted to the resulting article. Rather, the shape of the moldsurface (including the depressions) was imparted to the article.

Example 3-1

The hardenable fluid contained 20 weight percent polyvinyl alcohol,which is commercially available under the trade designation KURARY POVALPVA-205 from Kurary Co., Ltd., and 80 weight percent distilled water.This hardenable fluid was a water-soluble resin. A polypropylene sheet,identical to the sheet used in Example 2-1, was used as the mold.

The coating process was performed as described in Example 2-1 except forthe liquid resin. More specifically, the water-soluble resin was coatedon the mold using a knife coater, thereby forming a coating layer with athickness of 200 μm. The coating speed was 16 cm/sec and air wasentrapped around the mold.

The coating layer was subsequently dried for two hours in the oven at 60degree C. The coating layer was further dried at room temperatureovernight to form a hardened layer. The hardened layer was removed fromthe polypropylene mold, thus obtaining an article having concavesurfaces made of a water-soluble resin (the article had an arrangedpattern of concavities). The curvature of the concave surfaces wassmaller than those of Example 2-1.

Example 3-2

Using the article having concave surfaces manufacture in Example 3-1 asthe second mold, a UV curable resin identical to that used in Example2-1 was coated on the second mold with a thickness of 200 μm. The UVcurable resin layer was placed in contact with a 50 μm PET film. Adeaeration process was performed by reducing the atmosphere pressure inthe same manner as Example 2-2. Then, a hardened layer was formed byirradiating the UV curable resin from the PET film side with ultravioletrays of 3450 mJ/cm² using the same ultraviolet lamp used in Example 2-1.After polymerization, the hardened layer was removed from the secondmold to obtain an article made of a UV curable resin having convexsurfaces (the article had an arranged pattern of convexities).

Example 3-3

Articles were prepared using a process similar to that described inExample 3-1 but with different concentrations of polyvinyl alcohol inthe hardenable fluid. The polyvinyl alcohol is commercially availableunder the trade designation KURARAY POVAL PVA-205 from Kurary Co., Ltd.Distilled water was mixed with the polyvinyl alcohol to prepare aqueousmixtures respectively having 5 wt % of PVA-205, 10 wt % of PVA-205, 15wt % of PVA-205, 25 wt % of PVA-205, and 30 wt % of PVA-205. After thepreparation of the hardenable fluid compositions, each sample was coatedon the polypropylene mold shown in FIG. 2A at a thickness of 200 μmusing a coating speed of 16 cm/sec.

Each coating layer was dried for two hours in the oven at 60 degree C.and further dried at room temperature (about 25 degree C.) overnight toform a hardened layer. Thereafter, each hardened layer was removed fromthe polypropylene mold, thus obtaining articles with concave surfacesmade of polyvinyl alcohol.

In the SEM images observed substantially vertically above the concavesurfaces, the maximum diameters of the concave surface portions weremeasured at five positions. The average value of the measurements wasdetermined to be the average diameter of the concave surfaces.

Table 3 shows the relationship between the viscosity (concentration) ofthe water-soluble resin and the average diameter of the concave surfacesfor this embodiment.

TABLE 3 Drying Coating Curable temperature, Concentration, Viscosity,speed, Ave. diameter, resin ° C. weight percent mPa-sec cm/secmicrometers PVA-205 60 to 25 5 9 16 72.05 10 40 77.20 15 180 83.33 20500 89.09 25 3000 90.48 30 7000 87.94

Example 3-4

A manufacturing process similar to that described for Example 3-1 wasused. A 20 weight percent aqueous mixture of polyvinyl alcoholwater-soluble resin (KURARY POVAL PVA-205 from Kurary Co., Ltd.) wasprepared. Using the polypropylene mold as described in Example 2-1, sixsamples were prepared by coating the water-soluble resin on the mold ata thickness of 200 μm and with a coating speed of 16 cm/sec.

The first sample was dried for two hours in the oven at 25 degree C.,the second sample was dried for two hours in the oven at 60 degree C.,the third sample was dried for two hours in the oven at 80 degree C.,the fourth sample was dried for two hours in the oven at 100 degree C.,the fifth sample was dried for two hours in the oven at 120 degree C.,and the sixth sample was dried for two hours in the oven at 140 degreeC. Then, the six samples were dried at room temperature overnight, thusforming hardened layers. Thereafter, the hardened layers were removedfrom the polypropylene molds, thus obtaining six articles having concavesurfaces made of a water-soluble resin.

In the SEM image of the concave surface portions observed substantiallyvertically above, the maximum diameters (diagonal distances in case ofthe samples dried at a temperature of 120 degree C. or more) of theconcave surface portions whose shapes were measured at five positions.The average value of the measurements was determined to be the averagediameter of the concave surfaces.

Table 4 shows the relationship between the drying temperature and theaverage diameter of the concave surfaces in one embodiment of theinvention.

TABLE 4 Drying Coating Curable temperature, Concentration, speed, Ave.diameter, Resin ° C. weight percent cm/sec micrometers PVA-205 25 20 1663.84 60 91.80 80 97.12 100 95.84 120 105.18 140 105.70

Example 3-5

As in Example 3-1, a 20 weight percent aqueous mixture of polyvinylalcohol as a water-soluble resin (KURARY POVAL PVA-205 from Kurary Co.,Ltd.) was prepared. Then, the solution was coated on the mold whileentrapping air around the mold at the coating speeds of 1.44 cm/sec,4.03 cm/sec, and 23.36 cm/sec.

Then, the three coating layers were dried for two hours in the oven at60 degree C., and dried further at room temperature overnight, thusforming hardened layers. Thereafter, all of the hardened layers wereremoved from the polypropylene mold, thus obtaining articles havingconcave surfaces made of a water-soluble resin (article having anarranged pattern of concavities).

In the SEM images of the concave surface portions observed substantiallyvertically above, the maximum diameters of the concave surface portionswere measured at five positions. The average value of the measurementswas determined to be the average diameter of the concave surfaces.

Table 5 shows the relationship between the coating speed for thewater-soluble resin mixture and the average diameter of the concavesurfaces in one embodiment of the invention.

TABLE 5 Drying Coating Curable temperature, Concentration, speed, Ave.diameter, Resin ° C. weight percent cm/sec micrometers PVA-205 60 to 2520 23.36 95.13 4.03 94.44 1.44 90.55

Example 4-1

As the hardenable fluid in this example, a thermoplastic resin was used.More specifically, the thermoplastic resin was polyethylene,commercially available under the trade designation LDPEC13 from EastmanChemical Japan Co., Ltd. A nickel sheet having a square lattice patternof quadrangular pyramid depressions was used as the mold. Thesequadrangular pyramid depressions were 25 μm in depth, had an apex angleof 90 degree C., and a square bottom shape. Each side of the squarebottom was 50 μm and the convexities were arranged at pitches of 50 μm.The nickel sheet was prepared as described in Example 2-4.

The thermoplastic resin was coated on the mold using a heated knifecoater, thus forming a coating layer. More specifically, thethermoplastic resin was heated to a temperature (140 degree C.) at whichthe resin would have a sufficient fluidity, and was coated on the moldat a coating speed of 16 cm/sec to the thickness of 200 μm whiletrapping the air around the mold.

Then, the coating layer was cooled down to room temperature, thusforming a hardened layer. Thereafter, the hardened layer was removedfrom the nickel mold, thus obtaining an article having concave surfacesmade of a thermoplastic resin (the article had an arranged pattern ofconcavities).

Example 4-2

Using the article having concave surfaces manufactured in Example 4-1 asthe second mold, the UV curable resin which is the same as one used inExample 2-1 was coated on the second mold to the thickness of 200 μm. A50 μm PET film was placed in contact with the UV curable resin and thenpressed with a roller. A deaeration process was performed by reducingthe atmosphere pressure in the same manner of Example 2-2. Then, thesame ultraviolet lamp as used in Example 2-1 was used to irradiate theUV resin from the PET film side with ultraviolet rays of 3450 mJ/cm².The UV curable resin was polymerized to form a hardened layer. Afterpolymerization, the hardened layer was removed from the second mold,thus obtaining an article made of a UV curable resin having convexsurfaces (article having an arranged pattern of convexities).

Example 5-1

A multilayer film was provided that had a copper layer with a thicknessof 5 μm on a polyimide sheet with a thickness of 75 μm. The film iscommercially available under the trade designation TWO LAYER COPPER CLADSUBSTRATE from Japan Interconnection Systems Limited. A laser beam wasirradiated onto the polyimide side of the resulting multilayer film toform a depression, thus manufacturing a mold. The polyimide layercorresponds to the side wall portion (first layer 110 a) and the copperlayer corresponds to the bottom portion (second layer 110 b) in FIG. 7A.

More specifically, Beam, Inc. (Tokyo, Japan) prepared the openings inthe polyimide layer. An excimer laser beam was irradiated on thepolyimide layer side using a mask to form an opening array pattern onlyin the polyimide layer and a surface of the copper layer was exposed atthe bottom of each opening, thereby manufacturing a mold havingdepressions arranged in a square lattice pattern. Each depression hadcylindrical concavities. In this case, a mold #1 and a mold #2 whichhave different arranged patterns as shown in Table 6 were prepared bytwo kinds of masks.

TABLE 6 Diameter of opening, micrometers Thickness of Thickness ofPitch, Top - Bottom - Polyimide layer, Cu layer, Mold micrometersPolyimide side Cu side micrometers micrometers #1 250 151.63 137.01 75 5#2 80 50.54 36.34 75 5

The mold #1 had 100 depressions (10×10 lattice) in the form ofcylindrical concavities formed at pitches of 250 μm, and eachcylindrical concavity has a sectional shape with a diameter of 151.63 μmat a top surface side and a diameter of 137.01 μm at a bottom surfaceside (cupper layer side). The mold #2 has 100 depressions (10×10lattice) in the form of cylindrical concavities formed at pitches of 80μm, and each cylindrical concavity has a sectional shape with a diameterof 50.54 μm at a top surface side and a diameter of 36.34 μm at a bottomsurface side (cupper layer side).

FIG. 10A is a plane view from the top showing the mold #1 (110A) havingopenings 115A and FIG. 10B is a plane view from the top showing the mold#2 (110B) having openings 115B.

Example 5-2

An article having concave surfaces was manufactured using the abovementioned mold #1. As a hardenable fluid for this example, a UV curableresin was prepared by mixing 90 parts by weight of a UV hardenableoligomer, polyester based urethane acrylate (commercially availableunder the trade designation EBECRYL 8402 from DAICEL-CYTEC Co., Ltd.),10 parts by weight of an unsaturated aliphatic acid hydroxylalkylestermodifier ε-carprolactone (commercially available under the tradedesignation PLACEL FA2D from Daicel Chemical Industries, Ltd.), and 1parts by weight of a photo polymerization initiator (commerciallyavailable under the trade designation IRGACURE 2959 from CIBA SpecialtyChemicals Inc.

An etchant for removing the cupper layer after forming a hardenedcoating layer was prepared by mixing 6.4 parts by weight hydrogenperoxide, 18 parts by weight concentrated sulfuric acid, 33 parts byweight copper sulfate, and 42.6 parts by weight distilled water.

The UV curable resin was coated on the mold using a knife coater,thereby forming a coating layer. More specifically, the UV curable resinwas coated on the mold at a thickness of 200 μm while entrapping airaround the mold at the coating speed of 16 cm/sec in the same manner ofExample 2-1. Then, the UV curable resin was irradiated with ultravioletrays of 3450 mJ/cm² using the ultraviolet lamp of Example 2-1. The UVcurable resin was hardened (e.g., polymerized and cured).

After hardening, the copper layer (bottom portion) was removed using theetchant heated to 45 degree C. The resulting article was rinsed withdistilled water. The article had concave surfaces (the article had anarranged pattern of concavities). FIG. 11 shows a perspective view ofthe obtained article 131′A having concave surfaces 132A. As thepolyimide portion does not exist between adjacent concave surfacesarranged in a square lattice pattern in the article, the article havingconcave surfaces in which any groove-like portion did not exist betweenadjacent concave surfaces could be obtained.

An article having convex surfaces was manufactured using the articlemanufactured with concave surfaces. The curable resin was a mixturecontaining 20 weight percent polyvinyl alcohol as a water-soluble resin(commercially available under the trade designation KURARY POVAL PVA-217from Kurary Co., Ltd.) and 80 weight percent distilled water. Using thearticle having concave surfaces manufactured in Example 5-1 as thesecond mold, the 20 weight percent PVA-217 aqueous mixture was coated onthe second mold to the thickness of 200 μm using a knife coater. Adeaeration process was performed by reducing the atmosphere pressure inthe same manner of Example 2-2.

The hardened layer was obtained by drying the coating layer for twohours in the oven at 60 degree C. and at room temperature (about 25degree C.) overnight. After drying, the hardened layer was removed fromthe second mold, thus obtaining an article made of a polyvinyl alcoholresin having convex surfaces (the article had an arranged pattern ofconvexities). FIG. 12 shows a perspective view of the obtained article161A having convex surfaces 162A.

Each convex surface of the article was not surrounded by a groove-likeportion. That is, second article was obtained that had convex surfacesnot surrounded by a horizontal wall.

Example 5-3

An article having concave surfaces was manufactured using the mold #2instead of the mold #1. In this case, the article was manufactured usingthe same conditions Example 5-2 except for the mold.

FIG. 13 shows a perspective view of the obtained article 131′B havingconcave surfaces 132B. As with the article prepared in Example 5-2, anarticle was obtained that had concave surfaces without groove-likeportions between adjacent concave surfaces. An article having convexsurfaces was manufactured using the article manufactured as mentionedabove as a second mold. In this case, the second article wasmanufactured on the same conditions as the above mentioned Example 5-2except for the second mold.

FIG. 14 shows a perspective view of the obtained article 161B havingconvex surfaces 162B. As each concave surface of the second mold is notsurrounded by a groove-like portion, the second article has convexsurfaces that are not surrounded by a horizontal wall.

FIG. 16 is a schematic side-view of a display device 1600 that includesa pixilated liquid crystal panel 1610, an optical film 1620 thatincludes a structured major surface 1630 and a backlight 1640. Backlight1640 is a direct-lit backlight and includes a light diffuser plate 1670,multiple light sources 1650, and a back reflector 1660.

Structured major surface 1620 of optical film 1620 can be or include anystructured surface disclosed herein. For example, structured surface1620 can be the structured surface shown in FIG. 14 where each structureincludes a convexity and a sidewall. As another example, structuredsurface 1620 can be the structured surface shown in FIG. 13 where eachstructure includes a concavity and a sidewall, where in some cases, thesidewall can have a prism portion that can, for example, provide gainand/or redirect light to a desired direction. As another example,structured surface 1620 can be similar to the structured surface shownin FIG. 11 where each structure includes a concavity or a convexity butnot a sidewall. As yet another example, structured surface 1620 can bethe structured surface shown in FIG. 9 and include a plurality ofconcavities, where each concavity is surrounded by walls.

Optical film 1620 has an optical gain of at least 1.0, or at least 1.1,or at least 1.1, or at least 1.2, or at least 1.3, or at least 1.4, orat least 1.5, or at least 1.6. As used herein, “optical gain” of opticalfilm 1620 is defined as the ratio of the axial output luminance of anoptical system, such as display device 1600, with the optical film tothe axial output luminance of the same optical system without theoptical film.

In the exemplary display device 1600, structured major surface 1630faces pixilated liquid crystal panel 1610. In some cases, structuredmajor surface 1630 can face backlight 1640.

In the exemplary display device 1600, backlight 1640 is a direct-litbacklight. In some cases, backlight 1640 can be a side-lit backlight.For example, in some cases, backlight 1640 can be replaced with side-litbacklight 1740 a schematic side-view of which is shown in FIG. 17.Backlight 1740 includes a lightguide 1750, a back reflector 1780, alight source 1720 placed along a side 1745 of lightguide 1750, and aside reflector 1730.

1. A molding surface comprising a plurality of gas bubbles forming alattice pattern.
 2. The molding surface of claim 1, wherein the gasbubbles comprise concavities or convexities.
 3. The molding surface ofclaim 1, wherein the gas bubbles comprise linear side walls.
 4. Themolding surface of claim 1, wherein the lattice pattern comprises a rowpattern.
 5. The molding surface of claim 1, wherein the lattice patterncomprises a zigzag pattern.
 6. The molding surface of claim 1, whereinthe lattice pattern comprises a radial pattern.
 7. A surface comprisinga lattice pattern of concavities or convexities and a lattice pattern ofprisms.
 8. The surface of claim 7, wherein the concavities orconvexities comprise substantially spherical surfaces.
 9. The surface ofclaim 7, wherein the concavities or convexities have the same shape. 10.The surface of claim 7, wherein the concavities or convexities have thesame size.
 11. The surface of claim 7, wherein the concavities orconvexities are in direct contact with gas bubbles.
 12. The surface ofclaim 7, wherein the concavities or convexities are in direct contactwith a hardenable fluid.
 13. The surface of claim 7, wherein theconcavities or convexities are in direct contact with a hardened fluid.14. An article comprising a plurality of concavities, each concavitybeing surrounded by grooves.
 15. The article of claim 14, wherein theconcavities are arranged at predetermined positions.
 16. The article ofclaim 14, wherein the concavities form a lattice pattern.
 17. Thearticle of claim 14, wherein the grooves comprise prism portions. 18.The article of claim 14 further comprising a hardened fluid.
 19. Anarticle comprising a plurality of convexities, each convexity beingsurrounded by walls.
 20. The article of claim 19, wherein theconvexities are arranged at predetermined positions.
 21. The article ofclaim 19, wherein the convexities form a lattice pattern.
 22. Thearticle of claim 19, wherein the walls comprise prism portions.
 23. Thearticle of claim 19 further comprising a hardened fluid.
 24. An articlecomprising: a mold comprising a first structured surface comprising aplurality of walls separating a plurality of depressions; and ahardenable fluid covering the first structured surface of the mold andcontacting at least the plurality of the walls, such that if the fluidis hardened and removed from the mold, then the removed hardened fluidcomprises a second structured surface that is substantially differentthan the inverse of the first structured surface.
 25. The article ofclaim 24 wherein the second, but not the first, structured surface has aplurality of concavities or convexities.
 26. An article comprising: amold comprising a plurality of depressions; a fluid covering the mold;and one or more gas bubbles in each depression, the one or more bubblesforming a concavity in the fluid.
 27. The article of claim 26, whereinthe plurality of depressions form a lattice pattern.
 28. The article ofclaim 26, wherein each of the plurality of depressions has a pointedbottom.
 29. The article of claim 26, wherein each of the plurality ofdepressions has an edge line at the bottom.
 30. The article of claim 26,wherein each of the plurality of depressions comprises a pyramidportion.
 31. The article of claim 26, wherein each of the plurality ofdepressions comprises one or more planar sides.
 32. The article of claim26, wherein each of the plurality of depressions has a shape thattapers.
 33. The article of claim 26, wherein the one or more gas bubblesin each depression comprise a sidewall.
 34. The article of claim 26,wherein the concavity in the fluid comprises an over-hang portion.
 35. Adisplay device comprising: a backlight emitting light; a display paneldisplaying an image; and an optical film disposed between the backlightand the display panel and having an optical gain of at least 1.2, theoptical film comprising a structured major surface comprising aplurality of discrete structures, each structure comprising: a concavityor a convexity; and a side wall.
 36. The display device of claim 35,wherein the sidewall comprises a prism portion.
 37. The display deviceof claim 35, wherein the structured major surface of the optical filmfaces the backlight.
 38. The display device of claim 35, wherein thestructured major surface of the optical film faces the display panel.39. The display device of claim 35, wherein the concavity or theconvexity comprises a substantially spherical concavity or convexity.